Ford - Explorer Sport Trac 2wd - Workshop Manual - 2001 - 2001

Factory Workshop Manual Make Ford Model Explorer Sport Trac 2wd Engine and year V6-245 4.0L SOHC VIN K SFI (2001) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 9 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 10 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 11 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 16 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 17 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 18 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 19 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 20 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 21 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 22 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 P0110 - P0114: Testing and Inspection P0112 For diagnosis of code P0112 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 27 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 28 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 29 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 P0115 - P0119: Testing and Inspection P0116 For diagnosis of code P0116 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 34 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 35 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 36 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 37 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 38 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 43 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 44 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 45 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 46 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 47 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 52 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 53 P0125 - P0129: Testing and Inspection P0127 For diagnosis of code P0127 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 54 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 P0130 - P0134: Testing and Inspection P0131 For diagnosis of code P0131 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 59 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 60 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 61 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 66 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 67 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 68 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis P0140 - P0144: Testing and Inspection For diagnosis of code P0141 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > Page 72 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis P0145 - P0149: Testing and Inspection For diagnosis of code P0148 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > Page 76 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 P0150 - P0154: Testing and Inspection P0151 For diagnosis of code P0151 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 81 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 82 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 83 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 88 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 89 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 90 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis > Page 94 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 P0170 - P0174: Testing and Inspection P0171 For diagnosis of code P0171 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 99 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 100 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 101 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 102 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 103 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 P0175 - P0179: Testing and Inspection P0175 For diagnosis of code P0175 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 108 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 109 P0175 - P0179: Testing and Inspection P0176 For diagnosis of code P0176 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 110 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 115 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 116 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 117 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 118 P0180 - P0184: Testing and Inspection P0182 For diagnosis of code P0182 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 119 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 120 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 121 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 126 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 127 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 128 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 129 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 130 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 131 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 132 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 P0200 - P0204: Testing and Inspection P0201 For diagnosis of code P0201 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 138 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 139 P0200 - P0204: Testing and Inspection P0202 For diagnosis of code P0202 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 140 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 141 P0200 - P0204: Testing and Inspection P0203 For diagnosis of code P0203 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 142 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 143 P0200 - P0204: Testing and Inspection P0204 For diagnosis of code P0204 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 144 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 P0205 - P0209: Testing and Inspection P0205 For diagnosis of code P0205 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 149 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 150 P0205 - P0209: Testing and Inspection P0206 For diagnosis of code P0206 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 151 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 152 P0205 - P0209: Testing and Inspection P0207 For diagnosis of code P0207 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 153 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 154 P0205 - P0209: Testing and Inspection P0208 For diagnosis of code P0208 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 155 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 156 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 157 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 P0210 - P0214: Testing and Inspection P0210 For diagnosis of code P0210 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 162 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 163 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 164 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 165 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 166 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis P0215 - P0219: Testing and Inspection For diagnosis of code P0217 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > Page 170 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 175 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 176 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 177 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 178 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 179 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 180 P0230 - P0234: Testing and Inspection P0234 For diagnosis of code P0234 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 181 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244, ( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis P0240 - P0244: Testing and Inspection For diagnosis of code P0243 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244, ( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis > Page 185 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis P0295 - P0299: Testing and Inspection For diagnosis of code P0298 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > Page 189 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 195 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 196 P0300 - P0304: Testing and Inspection P0301 For diagnosis of code P0301 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 197 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 198 P0300 - P0304: Testing and Inspection P0302 For diagnosis of code P0302 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 199 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 200 P0300 - P0304: Testing and Inspection P0303 For diagnosis of code P0303 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 201 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 202 P0300 - P0304: Testing and Inspection P0304 For diagnosis of code P0304 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 203 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 P0305 - P0309: Testing and Inspection P0305 For diagnosis of code P0305 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 208 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 209 P0305 - P0309: Testing and Inspection P0306 For diagnosis of code P0306 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 210 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 211 P0305 - P0309: Testing and Inspection P0307 For diagnosis of code P0307 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 212 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 213 P0305 - P0309: Testing and Inspection P0308 For diagnosis of code P0308 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 214 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 215 P0305 - P0309: Testing and Inspection P0309 For diagnosis of code P0309 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 216 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis > Page 220 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis > Page 224 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 229 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 230 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 231 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 236 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 237 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 238 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis P0340 - P0344: Testing and Inspection For diagnosis of code P0340 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > Page 242 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 247 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 248 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 249 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 250 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 251 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 252 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 253 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 254 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 255 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 260 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 261 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 262 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 263 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 264 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 265 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 266 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 267 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 268 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis > Page 272 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 P0400 - P0404: Testing and Inspection P0400 For diagnosis of code P0400 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 278 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 279 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 280 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 281 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 282 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 283 P0400 - P0404: Testing and Inspection P0403 For diagnosis of code P0403 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 284 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 P0410 - P0414: Testing and Inspection P0411 For diagnosis of code P0411 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 289 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 290 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 291 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis > Page 295 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis > Page 299 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442 refer to chart DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information , See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 304 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 305 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 310 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 311 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 312 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 313 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 314 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455 refer to chart DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information , See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 319 P0455 - P0459: Testing and Inspection P0456 For diagnosis of code P0456 refer to chart DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information , See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 320 P0455 - P0459: Testing and Inspection P0457 For diagnosis of code P0457 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 321 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 326 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 327 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 328 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 P0500 - P0504: Testing and Inspection P0500 For diagnosis of P0500 refer to system experiencing problems. Engine Control System or Transmission Control System P0443 - P071x Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 334 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control System diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Wiper and Washer Systems DTC Index P0500 - B1432 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Wiper and Washer system diagnostic information, See: Wiper and Washer Systems/Testing and Inspection Transfer Case Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 335 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 336 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0443 - P071x NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 337 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 338 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0443 - P071x NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 339 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis P0505 - P0509: Testing and Inspection For diagnosis of code P0505 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > Page 343 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 348 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 349 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 350 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602 refer to chart P0443 - P071x NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to VID Block Procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 356 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 357 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 358 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis P0605 - P0609: Testing and Inspection For diagnosis of code P0605 refer to chart P0443 - P071x NOTE 14: Be sure to check for aftermarket performance products before replacing PCM. If replacement is necessary refer to Flash Electrically Erasable Programmable Read Only Memory (EEPROM), See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > Page 362 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 368 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 369 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 370 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 P0705 - P0709: Testing and Inspection P0705 For diagnosis of code P0705 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 375 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 376 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 377 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 P0710 - P0714: Testing and Inspection P0712 For diagnosis of code P0712 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 382 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 383 P0710 - P0714: Testing and Inspection P0713 For diagnosis of code P0713 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 384 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis P0715 - P0719: Testing and Inspection For diagnosis of code P0715 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission P0720 - P0724: Testing and Inspection Manual Transmission For diagnosis of code P072x refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 392 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 393 P0720 - P0724: Testing and Inspection Automatic Transmission P0720 For diagnosis of code P0720 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 394 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0721 For diagnosis of code P0721 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729, ( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis P0725 - P0729: Testing and Inspection For diagnosis of code P072x refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729, ( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis > Page 398 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 P0730 - P0734: Testing and Inspection P0731 For diagnosis of code P0731 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 403 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 404 P0730 - P0734: Testing and Inspection P0732 For diagnosis of code P0732 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 405 Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 406 P0730 - P0734: Testing and Inspection P0733 For diagnosis of code P0733 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 407 Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 408 P0730 - P0734: Testing and Inspection P0734 For diagnosis of code P0734 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 409 Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739, ( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis P0735 - P0739: Testing and Inspection For diagnosis of code P0735 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739, ( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis > Page 413 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 P0740 - P0744: Testing and Inspection P0741 For diagnosis of code P0741 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 418 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 419 P0740 - P0744: Testing and Inspection P0743 For diagnosis of code P0743 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 420 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis P0750 - P0754: Testing and Inspection For diagnosis of code P0750 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis P0755 - P0759: Testing and Inspection For diagnosis of code P0755 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis P0760 - P0764: Testing and Inspection For diagnosis of code P0760 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis > Page 430 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769, ( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis P0765 - P0769: Testing and Inspection For diagnosis of code P0765 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769, ( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis > Page 434 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 P0790 - P0794: Testing and Inspection P0791 For diagnosis of code P0791 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 439 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 440 P0790 - P0794: Testing and Inspection P0794 For diagnosis of code P0794 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 441 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis P0810 - P0814: Testing and Inspection For diagnosis of code P0812 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis > Page 446 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000 refer to chart P072x - P1138 NOTE 1: DTC P1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and continue as directed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 452 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 453 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 454 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 460 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 461 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 462 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 P1110 - P1114: Testing and Inspection P1112 For diagnosis of code P1112 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 467 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 468 P1110 - P1114: Testing and Inspection P1114 For diagnosis of code P1114 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 469 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 P1115 - P1119: Testing and Inspection P1115 For diagnosis of code P1115 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 474 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 475 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 476 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 477 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 478 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 483 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 484 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 485 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 486 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 487 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 492 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 493 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 494 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 495 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 496 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 497 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 498 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 P1130 - P1134: Testing and Inspection P1130 For diagnosis of code P1130 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 503 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 504 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 505 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 506 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 507 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 P1135 - P1139: Testing and Inspection P1137 For diagnosis of code P1137 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 512 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 513 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 514 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 519 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 520 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 521 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 522 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 523 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 P1155 - P1159: Testing and Inspection P1157 For diagnosis of code P1157 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 528 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 529 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 530 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 P1165 - P1169: Testing and Inspection P1168 For diagnosis of code P1168 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 535 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 536 P1165 - P1169: Testing and Inspection P1169 For diagnosis of code P1169 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 537 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 P1180 - P1184: Testing and Inspection P1180 For diagnosis of code P1180 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 542 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 543 P1180 - P1184: Testing and Inspection P1181 For diagnosis of code P1181 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 544 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 545 P1180 - P1184: Testing and Inspection P1183 For diagnosis of code P1183 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 546 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 547 P1180 - P1184: Testing and Inspection P1184 For diagnosis of code P1184 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 548 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229, ( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis P1225 - P1229: Testing and Inspection For diagnosis of code P1229 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229, ( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis > Page 553 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 P1230 - P1234: Testing and Inspection P1232 For diagnosis of code P1232 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 558 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 559 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1150 - P1401 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 560 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 561 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234 refer to chart P1150 - P1401 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 562 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 567 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 568 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 569 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 570 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 571 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 572 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 573 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis > Page 577 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 582 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 583 P1245 - P1249: Testing and Inspection P1246 For diagnosis of code P1246 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 584 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis P1260 - P1264: Testing and Inspection For diagnosis of code P1260 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > Page 588 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis P1270 - P1274: Testing and Inspection For diagnosis of code P1270 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > Page 592 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 597 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 598 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 599 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 600 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 601 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis > Page 605 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis > Page 609 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis > Page 614 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 P1380 - P1384: Testing and Inspection P1380 For diagnosis of code P1380 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 619 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 620 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 621 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 622 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 623 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 P1400 - P1404: Testing and Inspection P1400 For diagnosis of code P1400 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 629 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 630 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 631 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 636 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 637 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 638 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 639 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 640 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 641 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 642 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 P1410 - P1414: Testing and Inspection P1413 For diagnosis of code P1413 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 647 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 648 P1410 - P1414: Testing and Inspection P1414 For diagnosis of code P1414 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 649 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434, ( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis P1430 - P1434: Testing and Inspection For diagnosis of code P1432 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434, ( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis > Page 653 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444, ( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis P1440 - P1444: Testing and Inspection For diagnosis of code P1443 refer to chart DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information , See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 P1450 - P1454: Testing and Inspection P1450 For diagnosis of code P1450 refer to the system experiencing the problem. Computers and Control Systems P1405 - P1517 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 661 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 662 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 663 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 668 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 669 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 670 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 671 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 672 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 673 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 674 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 675 P1460 - P1464: Testing and Inspection P1464 For diagnosis of code P1464 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 676 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis > Page 680 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis > Page 684 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 P1475 - P1479: Testing and Inspection P1477 For diagnosis of code P1477 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 689 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 690 P1475 - P1479: Testing and Inspection P1479 For diagnosis of code P1479 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 691 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 697 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 698 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 699 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 700 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1405 - P1517 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 701 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 702 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 703 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 708 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 709 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 710 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 715 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 716 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 717 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 718 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 719 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 720 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 721 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis > Page 725 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis > Page 729 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis > Page 733 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574, ( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis P1570 - P1574: Testing and Inspection For diagnosis of code P1572 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574, ( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis > Page 737 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis P1605 - P1609: Testing and Inspection For diagnosis of code P1605 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis > Page 742 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis > Page 746 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635 refer to chart P1518 - P1781 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 751 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 752 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to chart P1518 - P1781 NOTE 18: DTC P1636 indicates the PCM has lost communication with the Inductive Signature Chip. Replace PCM. If replacement is necessary refer to Flash Electically Erasable Programmable Read Only Memory (EEPROM), See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 753 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 754 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to chart P1518 - P1781 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis P1640 - P1644: Testing and Inspection For diagnosis of code P1641 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > Page 759 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 764 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 765 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 766 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 P1700 - P1704: Testing and Inspection P1702 For diagnosis of code P1702 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 772 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 773 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to charts P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 774 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 775 P1700 - P1704: Testing and Inspection P1704 For diagnosis of code P1704 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 776 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 P1705 - P1709: Testing and Inspection P1705 Manual Transmission For diagnosis of code P1705 refer to chart P1518 - P1781 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission For diagnosis of code P1705 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 782 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 783 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 784 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 P1710 - P1714: Testing and Inspection P1711 For diagnosis of code P1711 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 789 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 790 P1710 - P1714: Testing and Inspection P1713 For diagnosis of code P1713 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 791 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 792 P1710 - P1714: Testing and Inspection P1714 For diagnosis of code P1714 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 793 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 P1715 - P1719: Testing and Inspection P1715 For diagnosis of code P1715 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 798 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 799 P1715 - P1719: Testing and Inspection P1716 For diagnosis of code P1716 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 800 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 801 P1715 - P1719: Testing and Inspection P1717 For diagnosis of code P1717 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 802 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 803 P1715 - P1719: Testing and Inspection P1718 For diagnosis of code P1718 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 804 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis P1725 - P1729: Testing and Inspection For diagnosis of code P1729 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > Page 808 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis P1740 - P1744: Testing and Inspection For diagnosis of code P1740 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > Page 812 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 P1745 - P1749: Testing and Inspection P1746 For diagnosis of code P1746 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 817 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 818 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 819 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 P1780 - P1784: Testing and Inspection P1780 For diagnosis of code P1780 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 824 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 825 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 826 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 827 P1780 - P1784: Testing and Inspection P1783 For diagnosis of code P1783 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 828 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission P1900 - P1904: Testing and Inspection Manual Transmission For diagnosis of code P1900 refer to charts P1783 - P1900 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission > Page 834 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission > Page 835 P1900 - P1904: Testing and Inspection Automatic Transmission For diagnosis of code P1900 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module Multifunction Electronic Control Modules: Locations Central Security Module Vehicles Built AFTER 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 845 Multifunction Electronic Control Modules: Locations Generic Electronic Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 846 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 847 Multifunction Electronic Control Modules: Locations Remote Anti-Theft Personality Module Vehicles Built BEFORE 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 850 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 853 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 855 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 858 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 859 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 861 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 863 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 864 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 865 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 866 Multifunction Electronic Control Modules: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 867 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 868 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 869 Multifunction Electronic Control Modules: Connector Views Central Security Module Vehicles Built AFTER 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 870 Generic Electronic Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 871 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 872 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 873 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 874 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 875 Remote Anti-Theft Personality Module Vehicles Built BEFORE 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 876 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 877 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 878 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 419-10-00-1 Diagram 419-10-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Diagram 419-10-00-3 Diagram 419-10-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 880 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into, the new module once installed. ^ Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description Module Controlled Functions NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. The multifunction module consists of the following: ^ Generic Electronic Module (GEM) ^ Remote Anti-theft Personality (RAP) module (vehicles built before 7/24/2000) ^ central security module (vehicles built after 7/24/2000) The GEM controls the following features: ^ front wiper and washer ^ rear wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp The remote anti-theft personality (RAP)/central security module controls the following features: ^ remote keyless entry ^ computer-operated locks Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 883 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) Central Security Module The central security module controls the following features: ^ remote key less entry system ^ computer-operated lock system Generic Electronic Module (Gem) NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal. The GEM receives inputs and delivers outputs to a majority of the electronically controlled features of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool through the ISO 9141 communication network. The GEM controls the following features: ^ front wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp Remote Anti-Theft Personality (RAP) Module The Remote Anti-theft Personality (RAP) module controls the following features: ^ remote keyless entry system ^ computer-operated lock system Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview Central Security Module (CSM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25 A) - 11 (7.5 A) ^ Wiring harness Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Generic Electronic Module (GEM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: - 10 (7.5A) - 20 (7.5A) - 25 (7.5A) - 28 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Remote Anti-Theft Personality (RAP) Module 1. Verify the customer concern by operating the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 886 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25A) - 11 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test C. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 887 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Chart B1213 - B1322 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 888 DTC Chart B1322 - B1345 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 889 DTC Chart B1347 - B1450 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 890 DTC Chart B1453 - B1602 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 891 DTC Chart B1610 - B1932 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 892 DTC Index B1933 - B2477 DTC Index B2477 - C1230 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 893 C1233 - P1826 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 894 P1827 - U2018 .. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 895 Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 896 Multifunction Electronic Control Modules: Pinpoint Tests B1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 897 B1 - B2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 898 A1 - A2 A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 899 C1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 900 C1 - C2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module Multifunction Electronic Control Modules: Service and Repair Central Security Module REMOVAL CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel. 3. Disconnect the electrical connectors. 4. Remove the central security module. 1 Remove the bolts. 2 Remove the central security module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module > Page 903 Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP) Module REMOVAL 1. Disconnect the battery ground cable. 2. Remove the back panel trim panel. 3. Disconnect the electrical connectors. 4. Remove the RAP module. 1 Remove the bolts. 2 Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module > Page 904 Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into, the new module once installed. 2. Remove the radio chassis. Refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM. 1 Remove the bolt. 2 Disconnect the electrical connectors from the GEM. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Page 905 Multifunction Electronic Control Modules: Tools and Equipment Special Tool(s) Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 911 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 912 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 913 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 914 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 916 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 917 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 918 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 919 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 920 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 921 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 922 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 923 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 924 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 925 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 926 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 927 Keyless Entry Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 929 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 930 Keyless Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 931 Keyless Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 932 Keyless Entry Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 939 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 948 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 949 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 950 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 954 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Keyless Entry Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 957 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 958 Keyless Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 959 Keyless Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 960 Keyless Entry Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 966 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 967 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 968 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 969 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 970 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 971 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 972 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 973 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 974 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 975 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 976 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 977 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 978 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 979 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 980 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 981 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 982 Power Door Lock Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 983 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 984 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 985 Power Door Lock Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 986 Power Door Lock Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 987 Power Door Lock Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Driver Door Unlock Relay Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Driver Door Unlock Relay > Page 992 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay > Page 995 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay > Page 996 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Page 997 Power Door Lock Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Page 998 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 1002 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-6-1 > Apr > 01 > Brakes ABS Lamp ON DTCB2607 May Be Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON DTCB2607 May Be Set Article No. 01-6-1 04/02/01 ^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY FORD: 2001 EXPLORER ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607 may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp may remain on or may illuminate intermittently. This may be due to the ABS module remaining active when the engine is cranked and both blower motors are on. ACTION Replace the ABS module with an updated module if existing module is the original design, and check for proper circuit grounding. Refer to the following Service Procedure for details. SERVICE PROCEDURE It the ABS lamp is on intermittently: 1. Replace the ABS module. a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Test drive vehicle to verify repair. If the ABS lamp is on continuously: 1. Replace the ABS module. a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 3. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-6-1 > Apr > 01 > Brakes ABS Lamp ON DTCB2607 May Be Set > Page 1012 b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 3. Verify if the vehicle is a 4X4 or 4X2. ^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded. ^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary. 4. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 5. b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 301000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON DTCB2607 May Be Set Article No. 01-6-1 04/02/01 ^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY FORD: 2001 EXPLORER ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607 may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp may remain on or may illuminate intermittently. This may be due to the ABS module remaining active when the engine is cranked and both blower motors are on. ACTION Replace the ABS module with an updated module if existing module is the original design, and check for proper circuit grounding. Refer to the following Service Procedure for details. SERVICE PROCEDURE It the ABS lamp is on intermittently: 1. Replace the ABS module. a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Test drive vehicle to verify repair. If the ABS lamp is on continuously: 1. Replace the ABS module. a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 3. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 1018 b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 3. Verify if the vehicle is a 4X4 or 4X2. ^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded. ^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary. 4. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 5. b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 301000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage Clutch Master Cylinder: All Technical Service Bulletins Clutch - Pedal Stays On Floor/Does Not Disengage Article No. 01-24-1 12/10/01 CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID LEAK FROM HYDRAULIC CLUTCH LINE FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or External Slave Cylinder. ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure for details. SERVICE PROCEDURE Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter pins. NOTE MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND F650-750. NOTE VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER) REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150. 1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave Cylinder (see previous notes) and the hydraulic line is disconnected or leaking. 2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder, External Slave Cylinder and system bleed procedure. 3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External Slave Cylinder. 4. Remove old quad seal from Master Cylinder and External Slave Cylinder. 5. Install new quad seal in Master Cylinder and External Slave Cylinder. 6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and External Slave Cylinder. 7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External Slave Cylinder). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 1024 8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall. Labor Operation Claiming Chart Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7C522 39 OASIS CODES: 505200, 506000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 1030 8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall. Labor Operation Claiming Chart Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7C522 39 OASIS CODES: 505200, 506000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1031 Electronic Brake Control Module: Specifications Control module bolts 13 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1032 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1033 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1034 Electronic Brake Control Module: Description and Operation Anti-Lock Brake Control Module NOTE: The new anti-lock brake control module must be reconfigured upon installation. The anti-lock brake control module is mounted to the HCU. It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and the necessary circuitry for their operation. The anti-lock brake control module monitors system operation during normal driving as well as during anti-lock braking. Anti-lock brake module operation is as follows: ^ Under normal driving conditions, the microprocessor produces short test pulses to the solenoid valves that check the electrical system without any mechanical reaction. ^ Impending wheel lock conditions trigger signals from the anti-lock brake control module that open and close the appropriate solenoid valves. This results in moderate pulsations in the brake pedal. During normal braking, the brake pedal feel will be identical to a standard brake system. Most faults that occur in the anti-lock brake system will be stored as a diagnostic trouble code (DTC) in the keep-alive memory of the anti-lock brake control module. The DTCs can be retrieved by following the on-board diagnostic procedures. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1035 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1036 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the electrical connectors. 3. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the anti-lock brake control module. 4. CAUTION: Once the new module is installed, the module configuration information may have to be entered. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Diagram 700-01-00-2 Diagram 700-01-00-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 1041 Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 1042 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay > Page 1045 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Page 1046 Blower Motor Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Page 1047 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1052 Compressor Clutch Relay: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1053 Compressor Clutch Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1054 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 1059 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 1060 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1067 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1073 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1074 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 Audible Warning Device Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 Audible Warning Device Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 Audible Warning Device Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 1088 Audible Warning Device Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1097 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1098 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1099 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1105 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1106 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1107 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1111 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1116 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1117 Battery Discharge Protection Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1118 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Diagrams > Page 1122 Courtesy Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Diagrams > Page 1123 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 1127 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 1128 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay > Page 1134 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 1135 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 1136 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 1140 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 1141 Hazard Flasher Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 1142 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1146 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1147 Horn Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1148 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Interior Lighting Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 Interior Lighting Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 Interior Lighting Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 Interior Lighting Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 1175 Interior Lighting Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 1179 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 1180 Interior Lighting Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 1181 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 1185 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 1186 Parking Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 1187 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Page 1191 Trailer Lighting Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Page 1192 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Page 1196 Turn Signal Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Page 1197 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 1202 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 1206 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1211 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1212 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1213 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1214 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1215 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1216 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1217 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1218 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1219 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1220 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1221 Relay Box: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1222 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1223 Relay Box: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1224 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1225 Relay Box: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1226 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1229 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1230 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1231 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1232 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1233 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1234 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1235 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1236 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1237 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1238 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1239 Relay Box: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1240 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1241 Relay Box: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1242 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1243 Relay Box: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1244 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1255 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1256 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1257 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's Powertrain Control Module: Customer Interest Instrument Panel - `Buzz' At Low Engine RPM's Article No. 01-4-10 03/05/01 NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD AT IDLE OR LOW SPEED DRIVING FORD: 2001 EXPLORER ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a "buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control Module (PCM) resonating against the heat shield that is located inside the PCM. ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section 303-14 for removal procedure. 2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the Rotunda Squeak and Rattle Kit, part number 164-R4900. 3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the top surface of the module at the rear center of the module. This will dampen the buzz noise from the PCM outer case. (Figure 1). 4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure. 5. Test drive vehicle to verify that the noise is corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 1262 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 702000, 702100, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1268 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1269 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1274 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1275 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1276 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's Powertrain Control Module: All Technical Service Bulletins Instrument Panel - `Buzz' At Low Engine RPM's Article No. 01-4-10 03/05/01 NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD AT IDLE OR LOW SPEED DRIVING FORD: 2001 EXPLORER ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a "buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control Module (PCM) resonating against the heat shield that is located inside the PCM. ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section 303-14 for removal procedure. 2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the Rotunda Squeak and Rattle Kit, part number 164-R4900. 3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the top surface of the module at the rear center of the module. This will dampen the buzz noise from the PCM outer case. (Figure 1). 4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure. 5. Test drive vehicle to verify that the noise is corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 1281 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 702000, 702100, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1287 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1288 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1289 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1290 Powertrain Control Module: Diagrams Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1291 Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1292 Powertrain Control Module: Description and Operation POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic tool manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and is incapable of communicating. Remove and replace the old PCM. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 1295 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1299 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1300 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1301 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation SOLID STATE RELAY Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1310 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1311 Fuel Pump Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1312 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1316 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1317 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1318 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1324 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1325 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1326 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1327 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1328 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1329 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1330 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1331 Air Bag Control Module: Specifications Restraints Control Module Bolts 12 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1332 Air Bag Control Module: Locations Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1333 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1334 Air Bag Control Module: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1335 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 1338 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 1339 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag supplemental restraint system (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 1340 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module Air Bag Control Module: Service and Repair Restraints Control Module With Side Air Bags SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1343 ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1344 4. Remove the retaining bolts and remove the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1345 SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1346 15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. Reconnect the battery ground cable. 19. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 21. Remove the full floor console. Vehicles with a restraint control module cover 22. Remove the mat, the screws and the Restraint Control Module (RCM) cover. 23. Remove the right-hand side RCM retaining bolts Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1347 24. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1348 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. 6. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1349 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover 8. Position the RCM cover. Install the screws and the mat. 9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1350 11. Position the lower steering column opening finish panel reinforcement and install the bolts. 12. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top seating the retaining clips. 2 Install the screws. 13. Position the hood release handle and install the screws. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1351 15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. Move and tilt the front seats to their highest and most forward position. 18. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 19. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 21. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1352 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 23. Connect the battery ground cable. 24. Position the front seats rearward. 25. Connect the battery ground cable. 26. With all the diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Without Side Air Bags SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1353 REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1354 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the retaining bolts and remove the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1355 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 12. Remove the full floor console. Vehicles with a restraint control module cover 13. Remove the mat, the screws and the Restraint Control Module (RCM) cover. 14. Remove the right-hand side RCM retaining bolts Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1356 15. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1357 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1358 6. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover 8. Position the RCM cover. Install the screws and the mat. 9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1359 10. Connect the clockspring electrical connector at the base of the steering column. 11. Position the lower steering column opening finish panel reinforcement and install the bolts. 12. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top seating the retaining clips. 2 Install the screws. 13. Position the hood release handle and install the screws. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1360 VEHICLE SAFETY STANDARDS. 15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. With all the diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1361 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 1362 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Page 1363 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1368 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1369 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1370 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1371 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1372 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1373 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1374 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 1379 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1384 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1385 Starter Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1386 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1391 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1392 Heated Glass Element Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1393 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations Power Window Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1401 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1402 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1403 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1404 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1409 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1411 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1412 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1413 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1414 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1415 Power Window Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1416 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1417 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1418 Power Window Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1419 Power Window Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1420 Power Window Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Diagram 700-01-00-2 Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Window Safety Relay Power Window Relay: Diagrams Window Safety Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Window Safety Relay > Page 1426 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay Power Window Relay: Testing and Inspection Window Safety Relay Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 1429 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 1430 Power Window Relay: Testing and Inspection One-Touch Window Relay Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 1431 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1438 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1439 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1440 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1441 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1442 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1443 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1444 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1445 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1446 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 Windshield Washer Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 Windshield Washer Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 Windshield Washer Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 1459 Windshield Washer Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay, Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay, Front > Page 1465 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 1466 Windshield Washer Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 1467 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1474 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1475 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1476 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1477 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1478 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 Wiper Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 Wiper Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 Wiper Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 1494 Wiper Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 1500 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 1501 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 1502 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 1503 Wiper Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 1504 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 1512 OASIS CODES: 201000, 201200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Side > Page 1517 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1520 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1521 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1522 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1526 Power Mirror Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1527 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 1533 Power Seat Switch: Vehicle Damage Warnings CAUTION: - Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags Power Seat Switch: Testing and Inspection Except Side Air Bags Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 1536 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 1537 Power Seat Switch: Testing and Inspection With Side Air Bags Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 1538 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag Power Seat Switch: Service and Repair With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1541 connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1542 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. 8. Using the special tool, remove the safety belt buckle support bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1543 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1544 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1545 21. Disconnect the clockspring electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 26. Remove the lumbar support knob. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1546 27. Remove the rear side shield screw. 28. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 29. Unhook the side shield from the seat latch. 30. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1547 31. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS OR THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1548 1. Install the 6-way power seat switch. 1 Install the 6-way power seat switch. 2 Install the screws. 2. Install the side shield. 1 Install the side shield. 2 Install the electrical connector. 3. Hook the side shield to the seat latch. 4. Install the side shield clips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1549 5. Install the rear side shield screw. 6. Install the lumbar support knob. 7. Position the driver seat into the vehicle. Install the four seat track to floor bolts and hand-tighten them. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 8. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1550 9. Connect the driver seat side air bag and power seat (if equipped) electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. 3 Tie-strap the wire harness. 10. Connect the battery ground cable. 11. Position the driver seat rearward. 12. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 13. Tighten the driver seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 14. Move and tilt the driver seat to its highest and most forward position. 15. Tighten the driver seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. 16. Install the driver seat rear track bolt covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1551 17. Connect the safety belt warning indicator electrical connector. 18. Using the special tool, install the safety belt buckle support bolt. 19. Install the safety belt buckle support bolt cover. 20. Position the driver seat rearward. 21. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 22. Position the passenger seat forward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1552 23. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 24. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 25. Position the passenger seat rearward. 26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 27. Install the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1553 28. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 29. Connect the clockspring electrical connector at the base of the steering column. 30. Position the lower steering column opening finish panel reinforcement and install the bolts. 31. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1554 32. Position the hood release handle and install the screws. 33. Connect the battery ground cable. 34. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 35. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1555 Power Seat Switch: Service and Repair Without Side Air Bag REMOVAL 1. Remove the front seat. 2. Remove the lumbar control knob, if equipped. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. 5. Remove the front seat cushion side shield screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 1556 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Remove the front seat cushion side shield. 8. Remove the 6-way power seat switch. - Remove the screws, then remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Page 1557 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 1561 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Position the overhead console aside. 2. Remove the roof opening panel control switch. 1 Remove the screws. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Ajar Switch Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1566 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1567 Trunk / Liftgate Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1568 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1573 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1574 Brake Fluid Level Sensor/Switch: Description and Operation Warning Switch, Brake Fluid Level The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations > Page 1578 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Front Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 8.5 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Front > Page 1586 Wheel Speed Sensor: Specifications Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 1589 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1592 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1593 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1594 Wheel Speed Sensor: Description and Operation Anti-Lock Brake Sensor NOTE: Any time an anti-lock brake sensor is removed, thoroughly clean the mounting surfaces. On front anti-lock brake sensors, apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. The anti-lock brake system uses three variable-reluctance sensors to determine vehicle speed. The anti-lock brake sensors operate on magnetic induction principle. As the teeth on the anti-lock brake sensor indicator rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and sent to the anti-lock brake control module through a twisted cable and shielded wiring harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control Wheel Speed Sensor: Service and Repair Rear Antilock Control Sensor-Rear Removal and Installation 1. Raise and support vehicle. 2. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. 3. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 1597 Wheel Speed Sensor: Service and Repair Sensor, Front Sensor-Front 4x2 Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front anti-lock brake sensor. 4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 1598 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor-Rear Removal and Installation NOTE: The rear anti-lock brake sensor indicator is attached to the differential case. For additional information, refer to Transmission and Drivetrain; Differential. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1604 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1605 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 1610 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 1614 Temperature Sensor (Gauge): Service and Repair Sender Unit-Water Temperature Indicator Removal and Installation 1. Partially drain the cooling system. 2. Remove the thermostat. 3. Disconnect the electrical connector. 4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1624 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1625 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1626 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1627 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1628 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1629 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1630 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1631 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1632 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1633 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1634 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1635 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1636 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1637 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1638 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1639 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1640 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1641 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1642 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1643 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1644 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1649 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1655 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1656 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1657 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1658 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1659 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1660 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1661 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1662 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1663 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1664 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1665 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1666 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1667 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1668 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1669 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1670 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1671 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1672 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1673 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1674 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1675 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1680 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 1681 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 1684 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 1685 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the speed control deactivator switch electrical connector. 3. Remove the speed control deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the screws and the steering wheel rear cover. 3. Remove the ribbon harness from the clips. 4. Disconnect the horn contact electrical connectors. 5. Remove the screws and the right side horn contact. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 1692 6. Remove the screws and the speed control switch assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams Blower Motor Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 1704 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 1705 Blower Motor Switch: Description and Operation Function Selector Switch The function selector switch combines a vacuum selector valve with two electrical switches to supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit. Temperature Control Switch Temperature selection is accomplished with a potentiometer connected to the electric blend door. Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a corresponding movement on the air temperature that the air system will maintain. Blower Motor Switch The blower motor switch controls blower motor speed by adding or by passing resistors in the heater blower motor switch resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 1706 Blower Motor Switch: Service and Repair CLIMATE CONTROL ASSEMBLY-FRONT SWITCHES REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1710 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Pressure Switch A/C High Pressure Switch Connector Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Pressure Switch > Page 1713 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops, The contacts close when the suction pressure rises. Refer to specifications regarding operating pressure(s). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of air flow. - It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the A/C cycling switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 1716 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch PCM Inputs AIR CONDITIONING CYCLING SWITCH The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See: Powertrain Management/Description and Operation/PCM Outputs NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - Standard Corporate Protocol (SCP) communication. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 1717 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure Switch The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on the Schrader valve stem. - This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises, the switch contacts open, disengaging the A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C compressor. Refer to specifications regarding operating pressure(s). - It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the A/C pressure cutoff switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection Dimmer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection > Page 1722 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pin 6 using a fused (10A) jumper to 12V DC power and pin 9 to ground. Measure the voltage between pin 8 and pin 9 while rotating the thumbwell from full illumination to no illumination. If the voltage smoothly decreases from near 12 volts to near 0 volts, the illumination dimmer is okay. If not, replace the main light switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Driver Side Door Switch: Diagrams Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Driver Side > Page 1727 Door Switch: Diagrams Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 1730 Door Switch: Service and Repair Door Ajar Switch-Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor > Page 1740 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 1744 Brake Pedal Position Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 1745 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Driver Side Door Switch: Diagrams Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Driver Side > Page 1750 Door Switch: Diagrams Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 1753 Door Switch: Service and Repair Door Ajar Switch-Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 1757 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1761 Hazard Warning Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1762 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1766 Headlamp Dimmer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1767 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1771 Headlamp Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1772 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1773 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel center finish panel. 1 Remove the screws. 2 Remove the instrument panel center finish panel. ^ Disconnect electrical connectors. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1774 5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the column gear shift lever out of the way. 7. Position the cluster finish panel aside. 1 Remove the screws. 2 Position the cluster finish panel aside. 8. Remove the cluster finish panel. 1 Disconnect the electrical connectors and remove the headlamp switch knob. 2 Remove the cluster finish panel. 9. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1775 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag. 2. Remove the switch. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the screws and the switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1782 Turn Signal Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1783 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1784 Turn Signal Switch: Service and Repair Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1785 5. Remove the multifunction switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multifunction switch. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 1790 OASIS CODES: 201000, 201200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP) sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1799 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1800 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1801 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1802 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1806 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1807 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1808 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 1812 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1816 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1817 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1821 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1822 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1823 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 1828 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 1832 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 1833 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1837 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1838 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE SENSOR Intake Air Temperature (IAT) Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type (Figure 37), are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1839 Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1843 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1844 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1849 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1850 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1851 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1852 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1853 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1854 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1855 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1856 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1857 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1858 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1859 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1860 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1861 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1862 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1863 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 1864 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 Heated Oxygen Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 Heated Oxygen Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 1888 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor Monitor The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper output voltage. The following illustration shows that input is required from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. 1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper function. 2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the Output State Monitor (OSM) and by measuring the current going through the heater circuit. The HO2S Monitor DTCs can be categorized as follows: The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130, P1131, P1132, P1150, P1151 and P1152. The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153. The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151 and P0156. The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in on-demand is DTC P1127. The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129. 3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive drive cycles. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 1891 Heated Oxygen Sensor: Description and Operation PCM Inputs HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 1892 Heated Oxygen Sensor: Service and Repair Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 2. Remove the Three Way Catalytic Converter (TWC). 3. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 1893 Socket, Exhaust Gas Oxygen Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1902 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1903 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1904 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1905 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1906 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1912 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1913 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1914 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1915 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1916 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1921 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1922 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1923 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1929 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1930 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1931 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1932 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1933 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1934 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1935 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1936 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1940 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 1943 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 1944 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1948 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1949 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1950 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1951 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1952 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 1956 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 1957 Vehicle Speed Sensor: Service and Repair Intermediate Shaft Speed (ISS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1. Remove the ISS sensor screw. 2. Remove the ISS sensor from the transmission. ^ Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the ISS sensor into the transmission. 2. Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 1958 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1968 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1969 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1970 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1971 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1972 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1978 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1979 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1980 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1981 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1982 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1987 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1988 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1989 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 01-24-1 > Oct > 01 > Clutch Pedal Stays On Floor/Does Not Disengage Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 01-24-1 > Oct > 01 > Clutch Pedal Stays On Floor/Does Not Disengage > Page 1995 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 01-24-1 > Oct > 01 > Clutch Pedal Stays On Floor/Does Not Disengage > Page 1996 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 01-24-1 > Oct > 01 > Clutch Pedal Stays On Floor/Does Not Disengage > Page 1997 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1998 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1999 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2000 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2001 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2002 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2007 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2008 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2009 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2010 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE SENSOR Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations Inertia Fuel Shutoff Switch The Inertia Fuel Shutoff (IFS) switch is on the RH A-pillar lower trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2017 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2018 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2019 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2023 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 2026 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 2027 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2032 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2033 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2034 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2038 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2039 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2040 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2046 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2047 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2051 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2052 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor Bolts 12 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right > Page 2059 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 2062 Impact Sensor: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 2063 Impact Sensor: Description and Operation WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS contains two sensors which are integral to the RCM. The RCM is mounted on the center tunnel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Side Crash Sensor, Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2066 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2067 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2068 SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2069 15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the diagnostic tools in place at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming 19. Position the front seats to their most forward position. 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 21. Pull to release the retaining clips and remove the windshield side garnish molding. 22. Pull up to release the retaining clips and remove the front door scuff plate. 23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2070 24. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26. Position the carpet aside at the front safety belt anchor. 27. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. 28. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2071 3 Remove the quarter trim panel front screw. 29. Fold the rear seat into the load floor position. 30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 31. Remove the retractable cargo cover. All Vehicles 32. Remove the rear safety belt guide. 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. 3 Remove the rear safety belt guide. 33. Position the carpet aside at the rear safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2072 34. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 35. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 36. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. 37. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2073 38. Remove the pin-type retainers from the quarter trim panel. 39. Slide the quarter trim panel forward and disengage it from the door jamb. 40. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2074 42. Position the side crash sensor with bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side crash sensor with bracket away from the B-pillar. 43. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2075 removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Connect the side crash sensor electrical connector. 1 Position the side crash sensor. 2 Connect the side crash sensor electrical connector. 2. Install the side crash sensor. 1 Position the side crash sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest and most forward position. 8. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2076 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 9. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbings through the openings in the quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 10. Slide back and engage the edge of the quarter trim panel into the door jamb. 11. Install the quarter trim panel rear screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2077 12. Through the front door opening, install the quarter trim panel front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim panel front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 13. Install the pin-type retainers into the quarter trim panel. 14. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 15. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Vehicles with a rear power lock switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2078 16. Connect and install the rear power lock switch assembly into the rear quarter trim panel. All vehicles 17. Position the washer on the rear safety belt guide bolt. 18. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 19. Fold the rear seat into the load floor position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2079 20. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 21. Reposition the carpet back over the floor. 22. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo covers 23. Install the retractable cargo cover. All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2080 24. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 25. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 26. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 27. Reposition the carpet at the front safety belt anchor. 28. Align the retaining clips and install the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2081 29. Align the retaining clips and install the windshield side garnish molding. 30. Reposition the rear seat back upward. 31. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 32. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 33. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2082 VEHICLE SAFETY STANDARDS. 34. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 35. Connect the battery ground cable. 36. Position the front seats rearward. 37. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 38. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 39. Install the passenger air bag module. 40. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2083 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 41. Connect the clockspring electrical connector at the base of the steering column. 42. Position the lower steering column opening finish panel reinforcement and install the bolts. 43. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 44. Position the hood release handle and install the screws. 45. Connect the battery ground cable. 46. With all the diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2084 Panel/Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 47. Check the restraint system for correct operation. Side Crash Sensor, Passenger Side Special Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2085 NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All Vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the passenger air bag module. 3. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 4. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2086 5. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 6. Remove the bolts and the lower steering column opening finish panel reinforcement. 7. Disconnect the clockspring electrical connector at the base of the steering column. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2087 DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2088 15. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the diagnostic tools in place at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming 19. Position the front seats to their most forward position. 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 21. Pull to release the retaining clips and remove the windshield side garnish molding. 22. Pull up to release the retaining clips and remove the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2089 23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. 24. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26. Position the carpet aside at the front safety belt anchor. 27. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2090 28. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. 3 Remove the quarter trim panel front screw. 29. Fold the rear seat into the load floor position. 30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 31. Remove the retractable cargo cover. All Vehicles 32. Remove the rear safety belt guide. 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2091 3 Remove the rear safety belt guide. 33. Position the carpet aside at the rear safety belt anchor. 34. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 35. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 36. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. 37. Remove the coat hook. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2092 1 Remove the screw. 2 Remove the coat hook. 38. Remove the pin-type retainers from the quarter trim panel. 39. Slide the quarter trim panel forward and disengage it from the door jamb. 40. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2093 42. Position the side crash sensor with the bracket away from the B-pillar. 1. Remove the bolts. 2. Position the side crash sensor with the bracket away from the B-pillar. 43. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM(SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2094 removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Connect the side crash sensor electrical connector. 1 Position the side crash sensor. 2 Connect the side crash sensor electrical connector. 2. Install the side crash sensor. 1 Position the side crash sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest and most forward position. 8. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2095 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS. NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 9. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbing through the openings in the quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 10. Slide back and engage the edge of the quarter trim panel into the door jamb. 11. Install the quarter trim panel rear screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2096 12. Through the front door opening, install the quarter trim panel front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim panel front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 13. Install the pin-type retainers into the quarter trim panel. 14. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 15. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2097 16. Position the washer on the rear safety belt guide bolt. 17. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 18. Fold the rear seat into the load floor position. 19. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 20. Reposition the carpet back over the floor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2098 21. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo covers 22. Install the retractable cargo cover. All Vehicles 23. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 24. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2099 ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 25. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 26. Reposition the carpet at the front safety belt anchor. 27. Align the retaining clips and install the front door scuff plate. 28. Align the retaining clips and install the windshield side garnish molding. 29. Reposition the rear seat back upward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2100 30. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 31. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 32. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 33. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2101 34. Connect the battery ground cable. 35. Position the front seats rearward. 36. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 37. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 38. Connect the clockspring electrical connector at the base of the steering column. 39. Position the lower steering column opening finish panel reinforcement and install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2102 40. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 41. Position the hood release handle and install the screws. 42. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 43. Install the passenger air bag module. 44. Connect the battery ground cable. 45. With all the diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 46. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2103 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 2104 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Page 2105 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safing sensor is internal to the RCM and is not serviced separately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2121 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2122 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 2126 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 2132 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 2133 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1. Remove the cover. 2. Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2137 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2138 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2139 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2140 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2141 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 2147 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 2148 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2160 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2161 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2162 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2164 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2165 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2166 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2167 Transmission Speed Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2168 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2169 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2170 Transmission Speed Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2172 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2173 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2174 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2180 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2181 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2184 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 2200 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 2207 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 2208 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 2211 Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 2212 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 2213 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 2214 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 2223 Power Window Switch: Diagrams Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 2224 Power Window Switch: Diagrams Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 2225 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2228 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2229 Power Window Switch: Testing and Inspection Power window Switch Passenger Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2230 Left Rear Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2231 Right Rear Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2232 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 2233 Power Window Switch: Service and Repair REMOVAL NOTE: Driver window control switch shown, all others are similar. Front door 1. Disconnect the battery ground cable. All doors 2. Remove the window control switch panel. ^ Disconnect the electrical connectors. 3. Remove the window control switch. ^ Release the locking clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2238 Windshield Washer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2239 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 2244 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 2245 Wiper Switch: Diagrams Multi-Function Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2246 Wiper Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2247 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2248 Wiper Switch: Service and Repair REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision TSB 04-24-19 12/13/04 REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer Sport Trac ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT NOTE THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT. 1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1). 2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision > Page 2254 3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. 4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward. 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 3084 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2255 Alignment: Specifications Alignment Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2256 General Specifications Related Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2257 Alignment: Description and Operation WHEEL ALIGNMENT ANGLES Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie-rod. Negative and Positive Camber Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Positive Toe (Toe In) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2258 Negative Toe (Toe Out) Toe The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2259 Ride Height Wheel Track Wheel Track Dogtracking Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2260 Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a readability problem, it is important to understand the difference between wander and poor groove feel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment 1. Remove the nuts and alignment plates. 2. Install the cams and the nuts. 3. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase the LF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2263 4. To decrease the LF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. 5. Tighten the nuts. 6. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase RF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 7. To decrease the RF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2264 8. Increase the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts forward. 9. Decrease the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts rearward. 10. Tighten the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2265 Alignment: Service and Repair Ride Height Ride Height 1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to normalize the vehicle static ride height. 3. Measure the distance between the center line of the front suspension lower arm bushing bolt and the lift. Record the measurement. 4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the measurement. ^ Take the measurement from the midpoint of the surface shown. 5. Determine ride height. ^ Subtract measurement 1 from measurement 2. This is the ride height. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2266 6. NOTE: The torsion bar adjusting bolt is coated with adhesive that wears off after disassembly. If the torsion bar system is ever disassembled or the torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when re-assembling. Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting bolt. ^ Tighten the torsion bar adjusting bolt to increase the torque or raise the height. ^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2267 Alignment: Service and Repair Toe Adjustment Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the manufacturer's instructions. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2268 6. Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 2275 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2276 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2277 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Flexible Fuel Idle Speed: Specifications With Flexible Fuel With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Flexible Fuel > Page 2282 Idle Speed: Specifications Without Flexible Fuel With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2290 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2291 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2295 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior Accelerator Pedal Vibration at 1500-1800 RPM > Page 2308 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 2314 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2315 Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2316 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL TOOL(S) REMOVAL 1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 3. Disconnect the spark plug wires from the separators and remove the spark plug wires. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2317 Spark Plug Wire Remover Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................... 1.3-1.4 mm (0.052-0.056 in.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2322 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ...................................................... 20 Nm (15 ft lbs) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2323 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... .............................................................. AGRF22PG LH Original Spark Plug ..................................... ................................................................................................................................................... AGRF22P New Spark Plug (Either Side) ............................................................................................ ................................................................................. AGSF22PP Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2324 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2328 Compression Check: Testing and Inspection Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the powertrain control module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 2335 Drive Belt: Service and Repair Accessory Drive Belt Removal and Installation 1. Remove the air cleaner outlet tube. 2. Remove the accessory drive belt. 1 Rotate the accessory drive belt tensioner counterclockwise. 2 Remove the belt. 3. NOTE: Refer to Component Locations for correct drive belt routing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions Evaporative Canister Filter: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions > Page 2346 Evaporative Canister Filter: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions > Page 2347 6. Disconnect the canister vent solenoid hose assembly. 7. Remove the evaporative emission dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission system. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Transmission Fluid Filter Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2351 Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Removal 1. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2352 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2353 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2354 ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2359 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2360 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2370 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2371 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2377 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2378 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: Customer Interest A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: All Technical Service Bulletins A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 2392 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 2393 Hose/Line HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for condenser to evaporator tube removal. 1 Disconnect the battery ground cable. 2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 3 Remove the air cleaner assembly. 2. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. Disconnect and remove the condenser to evaporator tube. INSTALLATION 1. To install, reverse the removal procedure. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 2394 Disconnect Tool Set, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Steering line to gear clamp plate nut 18 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 2398 Power Steering Line/Hose: Service and Repair Hose Special Tools Special Tool(s) Removal and Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 2399 1. Refer to the System View illustration for the hose routing and retention points. 2. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 3. Fill, purge and leak check the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Dot 4 may be used if Dot 3 is not available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 2404 Brake Fluid: Description and Operation Brake Fluid WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25A. ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Ford High Performance DOT3 Motor Vehicle Brake Fluid C6AZ-19542-AB ESA-M6C25-A, DOT3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2412 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Coolant: Pressure, Vacuum and Temperature Specifications Pressure Test Cooling System ................................................................................................................................... ...................................................................... 20 psi Thermostat Opening Temperature Starts To Open .................................................................................................................................... ................................................ 183 - 190 degrees F Fully Open ......................................................... .......................................................................................................................................... 210 degrees F Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2415 Coolant: Capacity Specifications Cooling System Capacity 14.0 qt (US) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2416 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ..................................................................... 10.0 qts Note: Approximately Dry Fill Capacity Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2421 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................................. MERCON V Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change Fluid - A/T: Service and Repair A/T Fluid Level Check and Condition, Change Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 2424 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 2425 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 2426 ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 2427 Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. 1. With the vehicle in PARK, position on a hoist. 2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail and positioned aside for fluid pan removal. If equipped, loosen the nut and position the heat shield aside. 3. Place a drain pan under the transmission fluid pan. 4. Drain the transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to drain. After the fluid is drained, remove the front two transmission fluid pan screws. 5. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 2428 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. Refill 1. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan ^ Loosely install the transmission fluid pan screws. 2. Tighten the transmission fluid pan screws. ^ Tighten the transmission fluid pan screws in a crisscross sequence. 3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the vehicle. 5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 2429 cross-hatched area of the fluid level indicator). 6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the gears. 8. Check the transmission fluid level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 2430 Fluid - A/T: Service and Repair Automated Equipment Transmission Fluid Drain and Refill-Automated Equipment Special Tool(s) Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. CAUTION: Always refer to the instructions supplied with the flush and fill machine. NOTE: This is a new procedure for draining and adding transmission fluid using a suitable transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will help remove any foreign material trapped in the fluid coolers. 4. Carry out the fluid exchange process. Refill 1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 2435 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 2436 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 2.7 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2439 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ............................................................. Mercon ATF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ............................................................. 5.5-5.8 pints Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2444 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Conventional ........................................................................................................................................ ..................................................................... 80W-90 Traction-Lok ..................................................... ...................................................................................................................................... 75W-140 Synthetic Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2449 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2450 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2451 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Engine Oil: Pressure, Vacuum and Temperature Specifications General Specifications Oil Pressure At 2,000 Rpm .................................................................................................................. ................................................................. 40 - 60 psi Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2454 Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2455 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................... SAE 5W-30 Motor Oil Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2460 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2461 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity ............................................................................................................................................... ......................................................... 0.85 kg (30 oz) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2466 Refrigerant: Fluid Type Specifications A/C Refrigerant .................................................................................................................................... ....................................... R-134a Refrigerant YN-19 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer Safety Information Refrigerant: Customer Safety Information WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT POSSIBLE PERSONAL INJURY . Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer Safety Information > Page 2469 Refrigerant: Environmental Impact Information The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer Safety Information > Page 2470 Fax: 215-541-4635 http://www.macsw.org/ Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer Safety Information > Page 2471 Refrigerant: Technician Safety Information WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE AIR BAG SYSTEM BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING ANY CLIMATE CONTROL COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. R-134A IS CLASSIFIED AS A SAFE REFRIGERANT, BUT MISUSE CAN MAKE IT DANGEROUS. THE FOLLOWING PRECAUTIONS MUST BE OBSERVED. ALWAYS WEAR SAFETY GOGGLES WHEN REPAIRING AN AIR CONDITIONING SYSTEM. - AVOID CONTACT WITH LIQUID REFRIGERANT R-134A. R-134A VAPORIZES AT APPROXIMATELY -25°C (-13°F) UNDER ATMOSPHERIC PRESSURE AND IT WILL FREEZE SKIN TISSUE. - NEVER ALLOW REFRIGERANT R-134A GAS TO ESCAPE IN QUANTITY IN AN OCCUPIED SPACE. R-134A IS NON-TOXIC, BUT IT WILL DISPLACE THE OXYGEN NEEDED TO SUPPORT LIFE. - NEVER USE A TORCH IN AN ATMOSPHERE CONTAINING R-134A GAS. R-134A IS NON-TOXIC AT ALL NORMAL CONDITIONS, BUT WHEN IT IS EXPOSED TO HIGH TEMPERATURES, SUCH AS A TORCH FLAME, IT DECOMPOSES. ONE OF THE PRODUCTS OF THE CHEMICAL BREAKDOWN IS A PHOSGENE GAS, WHICH IS HIGHLY TOXIC. - DO NOT ALLOW ANY PORTION OF THE CHARGED AIR CONDITIONING SYSTEM TO BECOME TOO HOT. THE PRESSURE IN AN AIR CONDITIONING SYSTEM RISES AS THE TEMPERATURE RISES AND TEMPERATURES OF APPROXIMATELY 85°C (185°F) CAN BE DANGEROUS. - ALLOW THE ENGINE TO COOL SUFFICIENTLY PRIOR TO PERFORMING MAINTENANCE OR SERIOUS BURNS AND INJURY CAN OCCUR. DUE TO REFRIGERANT HAZARDS, ALWAYS WEAR SAFETY GOGGLES AND NON-PENETRABLE GLOVES WHEN WORKING ON OR FLUSHING A/C SYSTEMS. USE EXTREME CARE AND OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS RELATED TO THE USE OF REFRIGERANTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Customer Safety Information > Page 2472 Refrigerant: Vehicle Damage Warnings CAUTION: To avoid damaging the vehicle or A/C components, the following precautions must be observed. The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging. Failure to due so can contaminate the shop bulk refrigerant and other vehicles. - Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These two types of refrigerant must never be mixed. Doing so can damage the A/C system. - Charge the A/C system with the engine running only at the low-pressure side to prevent refrigerant slugging from damaging the A/C compressor. - Use only R-134a refrigerant. Due to environmental concerns, when the air conditioning system is drained, the refrigerant must be collected using refrigerant recovery/recycling equipment. Federal law REQUIRES that R-134a be recovered into appropriate recovery equipment and the process be conducted by qualified technicians who have been certified by an approved organization, such as MACS, ASI, etc. Use of a recovery machine dedicated to R-134a is necessary to reduce the possibility of oil and refrigerant incompatibility concerns. Refer to the instructions provided by the equipment manufacturer when removing refrigerant from or charging the air conditioning system. - Refrigerant R-134a must not be mixed with air for leak testing or used with air for any other purpose above atmospheric pressure. R-134a is combustible When mixed with high concentrations of air and higher pressures. - A number of manufacturers are producing refrigerant products that are described as direct substitutes for Refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely damage the A/C components. If repair is required, use only new or recycled Refrigerant R-134a. - Use a back-up wrench to prevent damage to the tubes. To avoid contamination of the A/C system: Never open or loosen a connection recovering the refrigerant using approved equipment. - When loosening a connection, if any residual pressure is evident, allow it to leak out before opening the fitting. - Perform the Refrigerant Discharging and Recovery Procedure on a system that has been opened to install a new component or one that has discharged through leakage before charging. - Seal open fittings with a cap or plug immediately after disconnecting a component from the system. - Clean the outside of the fittings thoroughly before disconnecting a component from the system. - Do not remove the sealing caps from a new component until ready to install. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil container until ready to use, and install the cap immediately after using. Store the oil in a clean, moisture-free container. - Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal with refrigerant oil before connecting. - When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or any sharp edges that can chafe the line. - Tighten threaded fittings only to specifications. The steel and aluminum fittings used in the refrigerant system will not tolerate overtightening. - When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the refrigerant lines or tubes. - Do not open a refrigerant system or uncap a new component unless it is as close as possible to room temperature. This will prevent condensation from forming inside a component that is cooler than the surrounding air. - Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. - During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. - If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12 recovery/recycling equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure Special Tool(s) SPECIAL TOOL(S) NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. Refrigerant System Recovery 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. 2. Connect an R-134a A/C service center to the low- and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. 3. Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level on the gauge. If the vacuum does not decrease, disconnect the refrigerant center hose(s). 6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2475 Refrigerant: Service and Repair Identifying Refrigerants Delux A/C Refrigerant Analyzer SPECIAL TOOL(S) 1. Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the sample for testing. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. 2. The diagnostic tool will display one of the following: - If the purity level of R-134a or R-12 is 98% or greater by weight, the green "PASS" light emitting diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will be displayed on the digital display. - If refrigerants R-134a or R-12 do not meet the 98% purity levels, the red "FAIL" LED will light and a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light, "Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22,and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or greater. The diagnostic tool eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the diagnostic tool has determined that a refrigerant source is pure (R-134a or R-12 is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. 5. Perform the Refrigerant Discharging and Recovery Procedure to remove any contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12 recovery/recycling equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2476 Refrigerant: Service and Repair Handling of Contaminated Refrigerants 1. Perform the Refrigerant Discharging and Recovery Procedure to remove the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. - If this equipment is not available, contact an A/C repair facility in your area with the correct equipment to carry out this repair. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. 2. Determine and correct the cause of the customer's initial concern. 3. The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed. Remove the suction accumulator/drier. NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured for correct oil system matching. See: Refrigerant Oil Addition. 4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8. Dispose of contaminated refrigerant according to all federal, state and local regulations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2477 Refrigerant: Service and Repair Evacuation and Charging Special Tool(s) SPECIAL TOOL(S) NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. Refrigerant System Evacuation 1. Connect an R-134a service center to the low- and high-pressure service gauge port valves. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service the leak, and evacuate the system again. Refrigerant System Charging 1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. See: Refrigerant Oil Addition. 2. Charge the system with the specified amounts of refrigerant oil and refrigerant. 3. When no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation. Adjust the blower motor speed to the maximum and allow the remaining refrigerant to be drawn into the system. Continue to add refrigerant into the system until the specified weight of R-134a has been added. Close the charging cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2478 Refrigerant: Service and Repair Leak Detection Electronic Leak Detection Refrigerent Leak Detector SPECIAL TOOL(S) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. 1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 2. If a leak is found, Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. - Repair the system. - Test the system for normal operation. Tracer Dye Leak Detection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2479 120 Watt 110 Volt UV Lamp 20 Degree Celsius SPECIAL TOOL(S) NOTE: Ford Motor Company vehicles are produced with a permanent leak tracer dye incorporated into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak can exist, always inspect each component. 1. Check for leaks using a 120 Watt UV spot lamp. - Scan all components, fittings and lines of the A/C system. 2. After the leak is repaired, remove any traces of tracer dye with a general purpose oil solvent. 3. Verify the repair by operating the system for a short time and inspect with the UV spot lamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Capacity ............................................................................................................................................... ............................................................ 266 ml (9 oz) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2484 Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil R-134a Systems ................................................................................................................... F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2485 Refrigerant Oil: Service Precautions CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2486 Refrigerant Oil: Service and Repair CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. - Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2487 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice - installation of a new A/C compressor pressure relief valve - installation of a new refrigerant line - repair of an O-ring seal leak - repair of a charge port leak 6. Installation of new components that do not require you to Perform the Refrigerant Discharging and Recovery Procedure of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Disc brake caliper bleeder screw 15 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding Caliper WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2493 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Disc brake is shown, drum brake is similar. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2494 4. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2495 Brake Bleeding: Service and Repair Brake System Pressure Bleeding Pressure WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Disc brake is shown, drum brake is similar. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2496 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2497 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: This procedure only needs to be carried out if a new 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. NOTE: Disc brake is shown, drum brake is similar. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2498 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Repeat the bleed procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2499 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Master Cylinder Priming-In-Vehicle or Bench WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake component and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. 2. For bench priming, mount the brake master cylinder in a vise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2500 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, loosen the speed control pressure switch. 5. Slowly depress and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the brake pedal. 6. Tighten the speed control pressure switch. 7. Repeat the above three steps until no air bubbles are visible in the expelled fluid. 8. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 9. If necessary, install the brake master cylinder into the vehicle. 10. Remove the short brake tubes and install the master cylinder outlet tubes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2501 11. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 12. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 13. Tighten the outlet tube fitting at the HCU. 14. Repeat the above three steps until no air bubbles are visible in the expelled brake fluid. 15. Repeat the above four steps for the remaining master cylinder outlet tube. 16. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 17. Have an assistant pump and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2502 18. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 19. Tighten the master cylinder bleeder screw. 20. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 21. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 2503 Brake Bleeding: Tools and Equipment Special Tools Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor connector. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side floor connector. 11. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2508 STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector beneath the front seat. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag electrical connector beneath the front seat. 11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat. 12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side air bag electrical connector beneath the front seat. 13. Reconnect the battery ground cable. Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2509 NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2510 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2511 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2512 Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2513 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2514 Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2515 14. Install the two screws. 15. Close the glove compartment door. 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2516 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Procedures For Repair Operations Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2517 accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2518 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2519 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2520 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2521 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic tool from the driver seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2522 8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. Prove out the system. Seats Not Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the front passenger seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the driver seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver seat. 10. Reconnect the battery ground cable. 11. Prove out the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2523 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2524 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2530 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2531 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2532 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2533 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2534 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2535 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2536 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2537 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2538 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2539 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2540 Fuse: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2541 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2542 Fuse: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2543 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2544 Fuse: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2545 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 Fuse: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2569 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2570 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2571 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2572 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2573 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2574 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2575 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2576 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2577 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2578 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2579 Fuse: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2580 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2581 Fuse: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2582 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2583 Fuse: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2584 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2589 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2590 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2591 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2592 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2593 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2594 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2595 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2596 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2597 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2598 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2599 Fuse Block: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2600 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2601 Fuse Block: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2602 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2603 Fuse Block: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2604 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Fuse Block: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2629 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2630 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2631 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2632 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2633 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2634 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2635 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2636 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2637 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2638 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2639 Fuse Block: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2640 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2641 Fuse Block: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2642 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2643 Fuse Block: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2644 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2649 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2650 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2651 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2652 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2653 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2654 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2655 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2656 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2657 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2658 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2659 Relay Box: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2660 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2661 Relay Box: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2662 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2663 Relay Box: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2664 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2667 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2668 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2669 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2670 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2671 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2672 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2673 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2674 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2675 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2676 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2677 Relay Box: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2678 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2679 Relay Box: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2680 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2681 Relay Box: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2682 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > Resetting Oil Change Reminder Lamp Oil Change Reminder Lamp: Service and Repair Resetting Oil Change Reminder Lamp Oil Change Reset Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of 12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL CHANGE RESET control for five seconds. The message center will count down for five seconds. After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have established a personalized oil reset percentage, the display will show that percentage instead of 100%.) This reset procedure should be performed only after an oil change to ensure accurate oil life indications. Your personalized oil reset percentage allows you to establish a smaller oil change interval than the manufacturer's recommended interval. To establish your personalized oil reset percentage: 1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display is still counting gown the five seconds to reset. The display will change to START OIL LIFE AT XXX%. 2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil reset percentage you desire. Your choices are 100%, 90%, 80%, 70%, 60%, 50% 40% and 30%. 3. Press the RESET control to complete the procedure. Pressing any control other than RESET of OIL CHANGE RESET will abort this procedure and will not establish your new personalized oil reset percentage. When your personalized oil reset percentage has been established, it will be used beginning with the completion of your next OIL CHANGE RESET procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > Resetting Oil Change Reminder Lamp > Page 2691 Oil Change Reminder Lamp: Service and Repair No Reset Oil Life Mode The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. ^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL TRANSMISSION). Jacking Points - Front 1. The front jacking point is a tab that extends from the lower control arm. 1. The rear jacking points are located on the rear axle tube. CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2696 Lifting Points - 4x4 1. Locate front and rear hoist adapters on bottom lifting points as indicated. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2705 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2706 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2707 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2708 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2709 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2710 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2711 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2712 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2713 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2714 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Tires: Recalls Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2723 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2724 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2725 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2726 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2727 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2728 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2729 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2735 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2740 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2741 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2742 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2743 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2744 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2745 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2746 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2747 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2748 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2749 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement Technical Service Bulletin # 00L12 Date: 010101 Information 00L12 SPECIAL FIELD ACTION All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Original - January 2001 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Supplement # 1, February 5, 2001 - Updated Information All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Supplement # 2, February 19, 2001 - Updated Information All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2754 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2755 Attachment I - Administrative Information OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Attachment II - Labor Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2756 LABOR ALLOWANCES Attachment III - Technical Information SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico, and Canada, built through December 31, 2000. NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after December 31, 2000. SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2757 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2758 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2759 Supplement # 1 - Information Supplement # 1, February 5, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2760 Attachment III ^ Technical Information Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2761 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2762 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2763 Supplement # 1 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 1 - Attachment II Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2764 LABOR ALLOWANCES Supplement # 1 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2765 SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (included in this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2766 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2767 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2768 Supplement # 2 - Information Supplement # 2, February 19, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^Labor Allowances Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2769 Attachment III ^ Technical Information Apology Letter Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2770 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2771 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2772 Supplement # 2 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 2 - Attachment II Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2773 LABOR ALLOWANCES Supplement # 2 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2774 1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2775 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2776 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2777 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2786 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2787 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2788 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2789 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2790 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2791 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2792 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2798 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement Technical Service Bulletin # 00L12 Date: 010101 Information 00L12 SPECIAL FIELD ACTION All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Original - January 2001 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Supplement # 1, February 5, 2001 - Updated Information All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Supplement # 2, February 19, 2001 - Updated Information All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2803 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2804 Attachment I - Administrative Information OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Attachment II - Labor Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2805 LABOR ALLOWANCES Attachment III - Technical Information SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico, and Canada, built through December 31, 2000. NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after December 31, 2000. SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2806 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2807 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2808 Supplement # 1 - Information Supplement # 1, February 5, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2809 Attachment III ^ Technical Information Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2810 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2811 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2812 Supplement # 1 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 1 - Attachment II Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2813 LABOR ALLOWANCES Supplement # 1 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2814 SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (included in this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2815 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2816 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2817 Supplement # 2 - Information Supplement # 2, February 19, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^Labor Allowances Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2818 Attachment III ^ Technical Information Apology Letter Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2819 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2820 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2821 Supplement # 2 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 2 - Attachment II Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2822 LABOR ALLOWANCES Supplement # 2 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2823 1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2824 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2825 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2826 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2827 Tires: Specifications General Specifications Wheel Rim Runout Tire Runout Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2828 Tires: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the wheel nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1 Remove the wheel nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Clean the wheel hub mounting surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the wheel nuts hand-tight, then lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2829 3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in a star pattern, using a torque wrench or torque sticks. 4. Install the center cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Wheels: Recalls Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2843 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Wheels: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2853 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2854 Wheels: Specifications General Specifications Wheel Rim Runout Tire Runout Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire Removal 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the wheel nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1 Remove the wheel nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Clean the wheel hub mounting surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the wheel nuts hand-tight, then lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 2857 3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in a star pattern, using a torque wrench or torque sticks. 4. Install the center cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 2858 Wheels: Service and Repair Wheel Leaks 1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications - Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2862 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford Wheel Bearing: Service and Repair Ford Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Special Tools Special Tool(s) Removal 1. Remove the axle shaft. 2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 2865 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Special Tool(s) Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 2866 NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications - Tighten the spindle nut while rotating the brake disc and hub. - Loosen the spindle nut. - Tighten the spindle nut while rotating the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts 135 Nm (100 lb/ft) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal 1. Remove the brake disc and hub. 2. CAUTION: Place shop towels between the pry bars and the brake disc to prevent damage to the disc surface. Using two pry bars, remove the ABS sensor ring. Discard the ABS sensor ring. 3. Using a suitable press, remove the wheel stud from the brake disc and hub. Installation 1. Using a suitable press, install the wheel stud in the brake disc and hub. 2. CAUTION: When installing the ABS sensor ring, make sure the sensor ring is pressed on straight. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2876 Position a new ABS sensor ring on the hub. Using a cylinder with 79 mm (3.16 inch) inside diameter and 96 mm (3.84 inch) outside diameter, press the ring onto the hub until the ring seats against the shoulder in the hub. 3. Install the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2877 Wheel Fastener: Service and Repair Rear Special Tool(s) Special Tool(s) Removal CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the rear disc brake caliper, rear disc support bracket and brake disc, if so equipped. Support the rear disc brake caliper with safety wire. 4. Using the C-Frame and Screw Assembly, press the wheel stud from its seat and discard. Installation CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud. 1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned with those made by the original wheel stud. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2878 2. Seat new wheel studs in the axle flange. - Place four flatwashers over the outside end of the wheel stud. - Thread a standard wheel nut with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the flange. 3. Remove the wheel nut and flatwashers. 4. Install the brake disc, rear disc support bracket and the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. ^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL TRANSMISSION). Jacking Points - Front 1. The front jacking point is a tab that extends from the lower control arm. 1. The rear jacking points are located on the rear axle tube. CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2882 Lifting Points - 4x4 1. Locate front and rear hoist adapters on bottom lifting points as indicated. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 129). 1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and Crankshaft Position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Variable Cam Timing System HARDWARE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2890 Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing Unit Assembly Variable Cam Timing (VCT) Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2891 in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2892 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation VARIABLE CAM TIMING (VCT) SOLENOID VALVE Variable Cam Timing (VCT) Solenoid Valve The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2899 Compression Check: Testing and Inspection Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the powertrain control module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolts ................................................................................................................................... refer to procedure in service and repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Stage 1 50 Nm (37 lb-ft) Stage 2 Additional 90 degrees Camshaft Bolt 85 Nm (63 lb-ft) The right-hand camshaft sprocket bolt is a left-handed thread. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Intake Lobe Lift 0.259 in End Play 0.0003 - 0.007 in Exhaust Lobe Lift 0.259 in Maximum Allowable Lobe Lift Loss 0.005 in Journal to Bearing Clearance 0.002 - 0.004 in Journal Diameter 1.099 - 1.101 in Bearing Inside Diameter 1.102 - 1.104 in Maximum Camshaft Journal Runout 0.002 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH Camshaft: Service and Repair LH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Camshaft-LH Removal 1. Remove the camshaft roller followers. 2. Remove the LH hydraulic camshaft tensioner. 3. Remove the bolt and the camshaft sprocket. 4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in the original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube. 5. Remove the camshaft. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2912 1. NOTE: Lubricate the parts with clean engine oil before installing. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in the original position. NOTE: After installing the bolts, check the camshaft for free rotation. Position the oil supply tube, the camshaft bearing caps, and the bolts. ^ Tighten the bolts in the sequence shown in two stages. ^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.). ^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.). 3. The camshaft must be retimed. 4. Install the camshaft roller followers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2913 Camshaft: Service and Repair RH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Camshaft-RH Special Tool(s) Removal 1. Remove the camshaft roller followers. 2. Remove the RH hydraulic camshaft tensioner. 5. CAUTION: The right-hand camshaft sprocket bolt is a lefthand threaded bolt. Using the special tool, remove the bolt and the camshaft sprocket. 4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in the original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2914 5. Remove the camshaft. Installation 1. NOTE: Lubricate the parts with clean engine oil before installing. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in their original position. NOTE: After installing the bolts, check the camshaft for free rotation. Position the oil supply tube, the camshaft bearing caps, and the bolts. ^ Tighten the bolts in the sequence shown in two stages: ^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.). ^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.). 3. The camshaft must be re-timed. 4. Install the camshaft roller followers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Hydraulic Lash Adjusters Removal and Installation 1. Remove the camshaft roller followers. 2. Remove the hydraulic lash adjusters. 3. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Roller Followers Special Tools Special Tool(s) Removal 1. Remove the valve covers. 2. Remove the fuel supply manifold. 3. NOTE: Mark each camshaft roller follower to ensure its original position during reassembly. Using the special tool, remove the camshaft roller followers. 4. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 129). 1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and Crankshaft Position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Variable Cam Timing System HARDWARE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2925 Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing Unit Assembly Variable Cam Timing (VCT) Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2926 in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2927 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance to Crankshaft - Allowable ..................................................................................................................................................... 0.0005-0.002 inch Bearing Wall Thickness ......................................................................................... ............................................................................. 0.0551-0.0554 inch Connecting Rod Rod Bearing Bore I.D. ......................................................................................................................... .............................................................. 2.237 inch Rod Bearing Bore Out-of-Round ......................... ........................................................................................................................................... 0.0004 inch Rod Length Center to Center ....................................................................................................... ......................................................... 5.746 - 5.749 inch Alignment (Bore-to-Bore Maximum Difference) Twist .......................................................................................................... 0.0015 inch per 1.000 inch Alignment (Bore-to-Bore Maximum Difference) Bend ......................................................................................................... 0.00049 inch per 1.000 inch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2932 Connecting Rod Bearing: Service and Repair Connecting Rod Bearings Clearance to Crankshaft Allowable ......................................................................................................................................................... 0.0005 - 0.002 inch Bearing Wall Thickness ....................................................................................... ................................................................................. 0.0551 - 0.0554 inch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Bolt Install and tighten the connecting rod nuts finger tight. Tighten the connecting rod nuts simultaneously in two stages: ^ Stage 1: Tighten 20 Nm (15 ft. lbs.). ^ Stage 2: Tighten 90 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2937 Connecting Rod: Specifications Side Clearance (Assembled to Crankshaft) 0.092-0.268 mm Piston Pin Bore or Bushing I.D. 23.958-23.976 mm Rod Bearing Bore I.D. 56.82-56.84 mm Rod Bearing Bore Out-of Round 0.01 mm Rod Length Center to Center 145.965-146.035 mm Alignment (Bore-to-Bore Max. Diff.) - Twist 0.038 mm per 25.4 mm Alignment (Bore-to-Bore Max. Diff.) - Bend 0.0125 mm per 25.4 mm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Clearance to Crankshaft 0.0008 - 0.0015 in Clearance to Crankshaft Allowable 0.0005 - 0.002 in Bearing Wall Thickness 0.0709 - 0.0711 in Main Bearing Cap Bolts 72 ft. lbs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Cylinder Bore Diameter 3.953 in Maximum Cylinder Out-of-Round 0.001 in Maximum Cylinder Taper 0.001 in Main Bearing Bore Diameter 2.387 - 2.387 in Crankshaft to Rear Face of Block Runout. TIR Maximum 0.005 in Distributor Shaft Bearing Bore Diameter 2.852 - 2.853 in Head Gasket Surface Flatness 0.004 inch Overall Head Gasket Surface Finish RMS 60 - 150 Main Bearing Journal Diameter 2.243 - 2.244 in Main Bearing Journal Runout Limit 0.002 in Main Bearing Journal Taper Maximum Per Inch 0.003 in Connecting Rod Journal Maximum Out-of-Round 0.003 in Crankshaft Free End Play 0.002 - 0.0126 in Main Bearing Journal Out-of-Round 0.003 in Main Bearing Journal Runout TIR Maximum 0.002 in Main Bearing Journal Runout Service Limit 0.005 in Main Bearing Thrust Face Runout TIR Maximum 0.010 in Thrust Bearing Journal Length 1.039 - 1.041 in Main and Rod Bearing Journal Finish RMS Maximum 72 and 88 Main Bearing Thrust Face Finish RMS Maximum 20 Connecting Rod Journal Diameter 2.125 - 2.126 in Connecting Rod Journal Taper Per Inch Maximum 0.0003 in Clearance to Crankshaft Desired 0.0003 - 0.0024 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Block Heater Removal and Installation 1. Drain the cooling system. 2. Raise the vehicle. 3. Disconnect the block heater power cable from the block heater. 4. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal. Remove the block heater. 5. CAUTION: Make sure the power cable is routed and secured away from rotating or hot components or damage to the cable may occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt Stage 1 50 Nm (37 ft.lb) Stage 2 Additional 90 degrees Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2950 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Special Tools Special Tool(s) Removal 1. Remove the fan shroud. 2. Remove the accessory drive belt. 3. CAUTION: This bolt is torque to yield and cannot be reused. Remove the damper bolt. 4. Using the special tool, remove the crankshaft pulley. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2951 1. Using the special tool, install the crankshaft pulley. 2. Install a new crankshaft pulley bolt. ^ Tighten the bolt in two stages: ^ Stage l: Tighten the bolt to 50 Nm (37 ft. lbs.). ^ Stage 2: Tighten the bolt an additional 90 degrees. 3. Install the accessory drive belt. 4. Install the fan shroud. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Pin To Piston Pin Bore or Bushing I.D. 0.943 - 0.944 in Bore Clearance Selective Fit 0.0012 - 0.002 in Diameter-Coded STD 3.952 - 3.9528 in Diameter-Coded 0.5 3.972 in Diameter-Coded 1.0 3.990 - 3.991 in Pin Bore Diameter (Red) 0.945 in Pin Bore Diameter (Blue) 0.945 in Top Ring Groove Width 0.0645 - 0.0654 in Bottom Ring Groove Width 0.0705 - 0.0713 in Oil Ring Groove Width 0.1378 - 0.1399 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Length 2.835 - 2.866 in Diameter (Red) 0.9446 - 0.9447 in Diameter (Blue) 0.9447 - 0.9449 in To Piston Pin Bore Clearance 0.0004 - 0.0006 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Top Compression Ring Width 0.062 - 0.063 in Bottom Compression Ring Width 0.068 - 0.069 in Top Compression Side Clearance 0.002 - 0.0003 in Bottom Compression Side Clearance 0.002 - 0.003 in Top Compression Ring Gap 0.008 - 0.018 in Bottom Compression Ring Gap 0.018 - 0.028 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2968 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2969 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Roller Followers Special Tools Special Tool(s) Removal 1. Remove the valve covers. 2. Remove the fuel supply manifold. 3. NOTE: Mark each camshaft roller follower to ensure its original position during reassembly. Using the special tool, remove the camshaft roller followers. 4. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH Valve Cover: Service and Repair LH Valve Cover - LH Special Tool(s) Removal and Installation 1. Disconnect the battery negative cable. 2. Detach the accelerator and speed control cables. 1 Detach the accelerator and speed control cables from the throttle body. 2 Detach the accelerator and speed control cables from the bracket, and position the cables aside. 3. Detach the spark plug wire retainer. 4. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2977 NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Disconnect the spark plug wires. 5. Remove the bolts. 6. Remove the bolt. 7. Disconnect the coil electrical connector. 8. Disconnect the radio interference capacitor electrical connector and position the coil aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2978 9. Loosen the bolt and disconnect the electrical connector. 10. Disconnect the following: 1 Exhaust Gas Recirculation (EGR) valve vacuum hose. 2 EGR valve vacuum regulator solenoid vacuum hoses. 3 EGR valve vacuum regulator solenoid electrical connector. 4 Camshaft position sensor electrical connector. 5 Differential pressure feedback electrical connector. 11. Detach the spark plug wire retainer. 12. Disconnect the fuel vapor hose and the vacuum hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2979 13. Remove the bolt and position the electrical connector and bracket aside. 14. Remove the screws and the EGR valve vacuum regulator solenoid. 15. Remove the differential pressure feedback with the hoses from the exhaust manifold-to-EGR valve tube. 16. Relieve the fuel system pressure. 17. Detach the clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2980 18. Using the special tool, disconnect the fuel supply line. 19. Remove the bolt and position the fuel supply line aside. 20. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube. 21. Disconnect the hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2981 22. Unscrew fitting. 23. Remove the bolts and the valve cover. 24. To install, reverse removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2982 Valve Cover: Service and Repair RH Valve Cover - RH Removal and Installation 1. Drain the cooling system. 2. Remove the air cleaner outlet pipe. ^ Disconnect the tube. ^ Detach the Mass Airflow (MAP) sensor wiring pushpin. ^ Loosen the clamps and remove the pipe. 3. Release hose clamps and remove hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2983 4. Remove hose. 5. Disconnect the vacuum hose. 6. Loosen hose clamps and disconnect hoses. 7. Release hose clamps and disconnect hoses. 8. Release hose clamp and disconnect hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2984 9. Release hose clamp and disconnect hose. Position hose aside. 10. Remove the bolts. 11. Detach the wiring harness retainer. ^ Remove the heater tube and bracket assembly. 12. Disconnect MAF sensor connector and wiring pushpin. Position wiring aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2985 13. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Position the spark plug wires aside. 1 Disconnect the spark plug wires. 2 Disconnect the spark plug wire retainer and position the wires aside. 14. Disconnect fuel injector conductors. Position wiring aside. 15. Remove the bolts and the valve cover. 16. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve Guide Bore Diameter 0.276 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Width (Exhaust) 0.06 - 0.094 in Width (Intake) 0.05 - 0.083 in Angle Degrees 45 deg Runout TIR Maximum 0.002 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set Valve Spring: Customer Interest Engine Control - MIL ON, DTC P0300 or P0301 Set Article No. 02-3-2 02/18/02 ^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC, RANGER MERCURY: 1997-2002 MOUNTAINEER ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT "ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due to system interaction of higher than expected transient exhaust system backpressure (under heavy acceleration) coupled with valve spring resonance points experienced at these engine speeds. This interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher. ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust valve springs and replace with new service intake and exhaust valve springs. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S. NOTE PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set > Page 3000 1. Gain access to the valve springs. 2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with new service intake and exhaust valve springs 2L2Z-6513-AA. NOTE ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS. 3. Road test vehicle to verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 6513 42 OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set Valve Spring: All Technical Service Bulletins Engine Control - MIL ON, DTC P0300 or P0301 Set Article No. 02-3-2 02/18/02 ^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC, RANGER MERCURY: 1997-2002 MOUNTAINEER ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT "ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due to system interaction of higher than expected transient exhaust system backpressure (under heavy acceleration) coupled with valve spring resonance points experienced at these engine speeds. This interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher. ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust valve springs and replace with new service intake and exhaust valve springs. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S. NOTE PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set > Page 3006 1. Gain access to the valve springs. 2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with new service intake and exhaust valve springs 2L2Z-6513-AA. NOTE ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS. 3. Road test vehicle to verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 6513 42 OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Page 3007 Valve Spring: Specifications Intake Valve Spring Compression Pressure at Specified Height 202.84 - 224.968 ft. lbs. at 1.413 - 1.445 inch Exhaust Valve Spring Compression Pressure at Specified Height 202.84 - 224.968 ft. lbs. at 1.413 - 1.445 inch Intake Valve Spring Free Length 1.7 in Exhaust Valve Spring Free Length 1.7 in Intake Valve Spring Assembled Height 1.569 - 1.601 in Exhaust Valve Spring Assembled Height 1.569 - 1.601 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Page 3008 Valve Spring: Service and Repair Valve-Valve Spring Special Tools Special Tool(s) Removal and Installation 1. Remove the camshaft roller followers. 2. Position the piston at top dead center. 3. Hold the valve in the cylinder head. ^ Remove the spark plugs. ^ Use a suitable tool to apply air pressure to the cylinder. 4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. Using the special tool, remove the valve spring retainer keys, the valve spring and the retainer. 5. Inspect the components. 6. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Stem Diameter Intake 0.274 - 0.275 in Valve Stem Diameter Exhaust 0.274 in Valve Stem to Guide Clearance Exhaust 0.001 - 0.003 in Valve Stem to Guide Clearance Intake 0.001 - 0.002 in Head Diameter Intake 1.807 - 1.815 in Head Diameter Exhaust 1.531 - 1.539 in Valve Face Angle Degrees 45 deg Valve Face Runout Limit 0.001 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 3016 Drive Belt: Service and Repair Accessory Drive Belt Removal and Installation 1. Remove the air cleaner outlet tube. 2. Remove the accessory drive belt. 1 Rotate the accessory drive belt tensioner counterclockwise. 2 Remove the belt. 3. NOTE: Refer to Component Locations for correct drive belt routing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Removal and Installation 1. Remove the accessory drive belt. 2. Remove the accessory drive belt tensioner. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair Engine Mount: Service and Repair Engine Support Insulators Removal and Installation 1. Remove the fan shroud. 2. Remove the LH engine insulator nuts. 3. Remove the RH engine insulator nuts. 4. Raise and support the vehicle. 5. Remove the LH and RH engine support insulator nuts. 6. Raise and support the engine. 7. Remove the engine support insulators. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley Removal and Installation 1. Remove the accessory drive belt. 2. Remove the accessory drive belt idler pulley. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure at 2000 rpm 40-60 psi Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3034 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3035 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3036 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Engine Oil: Pressure, Vacuum and Temperature Specifications General Specifications Oil Pressure At 2,000 Rpm .................................................................................................................. ................................................................. 40 - 60 psi Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3039 Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3040 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................... SAE 5W-30 Motor Oil Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower Oil Pan Oil Pan: Service and Repair Lower Oil Pan Oil Pan Removal and Installation 1. Raise and support the vehicle. 2. Drain the engine oil. 3. Remove the bolts and the oil pan. 4. NOTE: All sealing surfaces must be cleaned prior to assembly. Use metal surface cleaner to clean the sealing surfaces. NOTE: Inspect integral oil pan gasket for cuts or damage that may cause leaks. Install a new gasket if necessary. NOTE: Fill the engine with clean engine oil. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the L (low) mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Page 3048 Oil Pressure Gauge: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube Removal and Installation 1. Remove the oil pan. 2. Remove the oil pump screen cover and tube. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure at 2000 rpm 40-60 psi Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake Manifold Bolts 10 Nm (89 in.lb) Throttle Body Bolts 9 Nm (80 in.lb) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 3062 Intake Manifold: Service and Repair Intake Manifold Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the bolts and the shield. 3. Remove the air cleaner outlet pipe. ^ Disconnect the tube. ^ Detach the Mass Airflow (MAF) sensor wiring pushpin. ^ Loosen the clamps and remove the pipe. 4. Disconnect the Idle air control (IAC) valve and the Throttle Position Sensor (TPS) electrical connectors. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 3063 5. Disconnect the accelerator and speed control cables. 1 Detach the accelerator and speed control cables from the throttle body. 2 Detach the accelerator and speed control cables from the bracket, and position the cables aside. 6. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube. 7. Disconnect the EGR valve vacuum regulator electrical connector and vacuum hoses. 8. Disconnect the hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 3064 9. Loosen the clamp and disconnect the brake booster vacuum hose. 10. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Disconnect the RH spark plug wires from coil. Remove spark plug wire routing clip pushpin and position the wires aside. 11. Remove wiring harness bracket retainer, then position wiring harness aside. 12. Remove accelerator cable routing clip pushpin and wiring harness pushpin. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 3065 13. Remove the bolts. 14. Remove the bolt and position the coil and bracket aside. 15. Disconnect the vacuum hoses. 16. Remove the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 3066 17. Disconnect the Powertrain Control Module (PCM) electrical connector. 18. Disconnect the ground wires and position the wiring harness aside. 19. Detach the electrical connector retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 3067 20. Remove the intake manifold bolts and lift up the intake manifold. 21. Remove the heated PCV hose retainers and remove the heated PCV fitting. 22. Remove the intake manifold. 23. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the L (low) mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Page 3072 Oil Pressure Gauge: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal Special Tool(s) Material Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3077 Removal 1. Remove the flexplate or flywheel. 2. Remove the crankshaft spacer plate. 3. Remove the crankshaft spacer. 4. CAUTION: Avoid scratching or damaging the crankshaft rear seal running surface during removal of the crankshaft rear seal. Using the special tool, remove the crankshaft rear seal. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3078 1. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear seal surface area, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface prep. Lubricate the crankshaft rear seal with clean engine oil and install it on the special tool. 2. Install the special tools. 3. Position the crankshaft rear seal and the special tool. 4. Using the special tool, install the crankshaft rear seal. 5. Install the crankshaft spacer. 6. Install the spacer plate. 7. Install the flexplate or flywheel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3083 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3084 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3085 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3086 Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3087 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3088 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Special Tool(s) Removal 1. Remove the crankshaft pulley. 2. Using the special tool, remove the crankshaft front oil seal. Installation 1. NOTE: Lubricate the seal lip with clean engine oil. Using the special tools and install the crankshaft front oil seal. 2. Install the crankshaft pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3100 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3101 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3102 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3103 DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3104 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3105 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3106 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3107 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3108 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3110 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3111 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3117 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3118 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3119 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3120 DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3121 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3122 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3123 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3124 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3125 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3126 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3127 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve-Valve Seals Special Tools Special Tool(s) Removal 1. Remove the valve springs. 2. Remove the valve stem seals. Installation 1. NOTE: Lubricate parts with clean engine oil prior to installing. Using the special tool, install the valve stem seals. 2. Install the valve springs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Stage 1 50 Nm (37 lb-ft) Stage 2 Additional 90 degrees Camshaft Bolt 85 Nm (63 lb-ft) The right-hand camshaft sprocket bolt is a left-handed thread. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3148 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3149 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3150 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3151 DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3152 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3153 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3154 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3155 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3156 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3157 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3158 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3159 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3165 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3166 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3167 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3168 DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3169 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3170 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3171 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3172 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3173 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3174 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3175 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3176 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3185 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3186 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3187 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3188 DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3189 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3190 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3191 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3192 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3193 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3194 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3195 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3196 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3202 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3203 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3204 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3205 DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3206 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3207 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3208 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3209 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3210 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3211 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3212 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3213 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Engine Front Cover Removal 1. Remove the radiator. 2. Remove the crankshaft pulley. 3. Remove the bolt and the wiring harness routing clip. 4. Remove the accessory bracket bolts and position the bracket aside. 5. Remove the drivebelt tensioner. 6. Disconnect the generator wiring and position the wiring aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3217 7. Remove the generator mounting bracket. 8. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 9. Remove the wiring anchors and position the wiring aside. 10. Remove the wiring harness retainer and position the wiring aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3218 11. Remove the thermostat housing. 1 Remove the bolts. 2 Release the bypass hose clamp. 12. Release the hose clamp and remove the lower heater water hose. 13. Release the hose clamp and remove the lower radiator hose. 14. On A/C equipped vehicles, remove the A/C line bracket bolt and position the A/C line aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3219 15. NOTE: The water pump is removed for clarity. Remove the engine front cover. Installation 1. Clean and inspect the sealing surfaces. 2. Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces. 3. Apply silicone gasket and sealant to the front cover in two places. 4. Install the engine front cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3220 5. On A/C equipped vehicles, install the A/C line bracket and bolt. 6. Install the lower radiator hose and clamp. 7. Install the lower heater water hose and clamp. 8. Install the thermostat housing. 1 Install the housing into the bypass hose. 2 Install the bolts. 3 Position the bypass hose clamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3221 9. Position the wiring harness and install the bolt. 10. Secure the wiring anchors. 11. Connect the CKP sensor electrical connector. 12. Install the generator mounting bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3222 13. Connect the generator wiring. 14. Install the drivebelt tensioner. 15. Install the accessory bracket bolts. 16. Install the routing clip and bolt. 17. Install crankshaft pulley. 18. Install the radiator. 19. Raise and support the vehicle. 20. Drain the engine oil. 21. Lower the vehicle. 22. Fill the engine oil with clean engine oil. 23. Fill the engine will coolant. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 129). 1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and Crankshaft Position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Variable Cam Timing System HARDWARE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3228 Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing Unit Assembly Variable Cam Timing (VCT) Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3229 in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3230 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation VARIABLE CAM TIMING (VCT) SOLENOID VALVE Variable Cam Timing (VCT) Solenoid Valve The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 3240 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3241 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3242 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Flexible Fuel Idle Speed: Specifications With Flexible Fuel With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Flexible Fuel > Page 3247 Idle Speed: Specifications Without Flexible Fuel With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3255 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3256 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3260 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 3273 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 3279 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3280 Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3281 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL TOOL(S) REMOVAL 1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 3. Disconnect the spark plug wires from the separators and remove the spark plug wires. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3282 Spark Plug Wire Remover Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................... 1.3-1.4 mm (0.052-0.056 in.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3287 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ...................................................... 20 Nm (15 ft lbs) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3288 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... .............................................................. AGRF22PG LH Original Spark Plug ..................................... ................................................................................................................................................... AGRF22P New Spark Plug (Either Side) ............................................................................................ ................................................................................. AGSF22PP Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3289 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3293 Compression Check: Testing and Inspection Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the powertrain control module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water Pump Bolts 89 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump > Page 3301 Water Pump: Specifications Water Pump Pulley Bolts 18 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3302 Water Pump: Service and Repair Water Pump Removal and Installation 1. Drain the engine cooling system. 2. Remove the accessory drive belt. 3. Remove the belt idler pulley. 4. Slide the water bypass hose clamp back. 5. Disconnect the heater hose at the water pump. 1 Release the clamp. 2 Remove the hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3303 6. Disconnect the lower radiator hose at the water pump. 1 Release the clamp. 2 Remove the hose. 7. Remove the water pump pulley. 8. Remove the water pump. 9. NOTE: Use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation Hydraulic Cooling Fan Solenoid Valve: Description and Operation HYDRAULIC COOLING FAN DRIVE Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 50) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 3313 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Coolant: Pressure, Vacuum and Temperature Specifications Pressure Test Cooling System ................................................................................................................................... ...................................................................... 20 psi Thermostat Opening Temperature Starts To Open .................................................................................................................................... ................................................ 183 - 190 degrees F Fully Open ......................................................... .......................................................................................................................................... 210 degrees F Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3316 Coolant: Capacity Specifications Cooling System Capacity 14.0 qt (US) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3317 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Coolant Expansion Tank Removal and Installation 1. Remove the air cleaner outlet tube and the engine air cleaner. 2. Remove the bolt and position the speed control servo aside. 3. Disconnect the windshield washer hose from under the dash panel and plug the end of the hose. 4. Disconnect the windshield washer pump electrical connector from the windshield washer reservoir. 5. Disconnect and plug the overflow hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Page 3321 6. Remove the two nuts and bolts, and the coolant expansion tank. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Cooling Fan Removal and Installation 1. Remove cooling fan shroud. 2. Remove the bolts. 3. Separate the fan blade from the fan clutch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Tools and Equipment Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation Hydraulic Cooling Fan Solenoid Valve: Description and Operation HYDRAULIC COOLING FAN DRIVE Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 50) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3336 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3337 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3342 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 3346 Temperature Sensor (Gauge): Service and Repair Sender Unit-Water Temperature Indicator Removal and Installation 1. Partially drain the cooling system. 2. Remove the thermostat. 3. Disconnect the electrical connector. 4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Cooling Fan Shroud Special Tool(s) Removal and Installation 1. Remove the air cleaner outlet tube. 2. Using the special tools remove the fan blade and clutch assembly. 3. Remove the bolts, and the fan blade and shroud. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair Heater Control Valve: Service and Repair REMOVAL 1. Prepare the vehicle for heater water control valve assembly removal. 1 Drain the engine coolant. 2 Remove the air cleaner assembly. 2. Disconnect the vacuum hose and heater hose. 3. Remove the retaining pins. Position the inner fender well access mat out of the way. 4. Disconnect the heater hose. Remove the bolt and the heater water control valve assembly. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water only, if needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3361 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3362 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3368 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3369 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3370 Heater Core: Service Precautions WARNING: - CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3371 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3372 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED ARE IN SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: the heater control valve is not working correctly. - the heater core may have an air pocket. - the heater core may be plugged. - the thermostat is not working correctly. Heater Core-Pressure Test Use Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3373 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3374 Heater Core: Service and Repair REMOVAL 1. Prepare the vehicle for heater core removal. 1 Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Heating and Air Conditioning/Evaporator Case/Service and Repair 2 Remove the Dash Board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3 Remove the Powertrain Control Module (PCM), please refer to Powertrain Management/Computers and Controls/Engine Control Module/Service and Repair/ See: Powertrain Management/Computers and Control Systems/Powertrain Control Module/Service and Repair NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 2. Remove the PCM heat sink 1 Remove the ground strap screw. 2 Remove the heat sink. 3. Remove the four nuts from the engine side of the dash panel. Position the plenum chamber on the vehicle floor. 4. Remove the heater core cover. 1 Remove the screws. 2 Remove the heater core cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3375 5. Remove the heater core. - During installation, be sure to install a new oval foam seal around the heater core inlet and outlet tubes. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3384 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3385 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3391 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3392 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection 1. Disconnect water temperature indicator sender unit C1061. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C1061, circuit 39 (RD/WH), harness side and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid-range. Key OFF. 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. Return to the Pinpoint Test. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Page 3397 Temperature Gauge: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Radiator Removal and Installation 1. Drain the cooling system. 2. Remove the air cleaner outlet tube. 3. Disconnect and remove the overflow hose. 4. Remove the cooling fan shroud. 5. Disconnect the upper radiator hose from the radiator. 6. Disconnect the lower radiator hose from the radiator. 7. Disconnect the two transmission cooling lines. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 3401 8. Remove the two bolts and the radiator. 9. Position aside EVAP test port. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3407 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3408 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3413 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 3417 Temperature Sensor (Gauge): Service and Repair Sender Unit-Water Temperature Indicator Removal and Installation 1. Partially drain the cooling system. 2. Remove the thermostat. 3. Disconnect the electrical connector. 4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection 1. Disconnect water temperature indicator sender unit C1061. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C1061, circuit 39 (RD/WH), harness side and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid-range. Key OFF. 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. Return to the Pinpoint Test. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Page 3421 Temperature Gauge: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat starts to open 90-94 C (183-190 F) Thermostat fully open 105 C (210 F) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3425 Thermostat: Description and Operation THERMOSTAT HEATER CONTROL Thermostat Assembly With Heater Control The primary objective for the thermostat heater control is for improvement in fuel economy and thermal efficiency. The system consists of a high temperature (98°C/208°F in lieu of a 90°C/194°F) thermostat (Figure 51)that has a resistive heater within the wax element. The heater is controlled by the PCM dependent on engine speed, throttle position, engine load, vehicle speed, air charge temperature, transmission oil temperature and engine coolant temperature. During low speed, low load and low air charge temperature conditions, the thermostat heater is OFF and the engine is allowed to operate at an elevated coolant temperature. This should result in lower internal friction and higher thermal efficiency, both leading to improved fuel economy. During high speed, high load, high temperature conditions (air charge, transmission oil or engine coolant), the PCM output is energized with a duty cycle to the thermostat heater. This heats the wax and forces the thermostat to rapidly open wider allowing extra coolant to flow from the radiator. This will reduce the coolant temperature and improve with performance demand. It should be noted that the heater is only capable of supplying a SMALL amount of additional heat to the wax element; it is NOT capable of opening the thermostat alone. The thermostat is 100% duty cycle for short calibrated time and than the duty cycle is reduce to a maximum of 70% on and 30% off. Approximately, unheated, the thermostat will begin to open at a coolant temperature of 98°C (208°F) and will be fully open at 115°C (239°F). Energizing the heater will reduce the opening temperature to about 80°C (176°F) and the fully open temperature to 110°C (230°F). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3426 Thermostat: Service and Repair Thermostat Removal and Installation 1. Drain the engine cooling system. 2. Remove the air cleaner outlet tube. 3. Remove the upper radiator hose extension. 4. Remove the bolts water outlet adapter and thermostat. ^ Inspect the O-ring seal, install a new O-ring seal if necessary. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water Pump Bolts 89 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump > Page 3431 Water Pump: Specifications Water Pump Pulley Bolts 18 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3432 Water Pump: Service and Repair Water Pump Removal and Installation 1. Drain the engine cooling system. 2. Remove the accessory drive belt. 3. Remove the belt idler pulley. 4. Slide the water bypass hose clamp back. 5. Disconnect the heater hose at the water pump. 1 Release the clamp. 2 Remove the hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3433 6. Disconnect the lower radiator hose at the water pump. 1 Release the clamp. 2 Remove the hose. 7. Remove the water pump pulley. 8. Remove the water pump. 9. NOTE: Use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3439 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3440 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3441 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3442 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3443 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3444 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3445 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3446 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3447 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3448 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3449 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3450 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3451 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3452 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3453 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions Catalytic Converter: Description and Operation Acronyms and Definitions 2V - L ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. 2V: Two Valve engine configuration. 4V: Four Valve engine configuration. ABS: Anti-lock Brake System. A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by cooling and dehydrating the air. ACC: Air Conditioning Clutch. Indicates status of the A/C clutch. ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch. ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel. ACP: Air Conditioning Head Pressure or A/C cycling switch input state. ACPSW: Air Conditioning Pressure Switch. ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module (PCM) from the ACP switch or sensor. ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout control during heavy acceleration. A/D: Analog-to-Digital. Analog-to-Digital signal conversion. ADC: See ATDC. AFCM: Alternative Fuel Control Module. AIR: Secondary Air Injection. AIRB: Secondary Air Injection Bypass. Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system when the electric air pump is commanded on. AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System has been evaluated for OBD (On-Board Diagnostic) II purposes. Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry. AIRM: Secondary AIR pump monitor. Ambient Air Temperature: Temperature of the air surrounding an object. Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits of the signal. ARB: Air Resource Board. ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by Speed Control Command Switch (SCCS) inputs. ASCII: American Standard Code for Information Interchange. ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke. Measured in degrees of crankshaft rotation. AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale, rather than a digital display. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3456 AWD: All-Wheel Drive. BARO: Barometric Pressure. Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC solenoid disconnected. Base Timing: Spark advance in degrees before top dead center of the base engine without any control from the PCM or ICM. Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected directly to the battery. Compare "Vehicle Power (VPWR)." BAT TEMP: Battery Temperature. BJB: Battery Junction Box. BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness. BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be hydraulic or electric. BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the Brake Pedal Position (BPP) switch. BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by applying voltage to the control line. BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its stroke. Measured in degrees of crankshaft rotation. Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to module and to the DLC. CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of pressurized intake air. CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which govern fuel economy standards. CANVNT: Canister Vent Solenoid. Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine exhaust emissions. CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency Monitor has successfully completed. CCM: Comprehensive Component Monitor. CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various EEC components. CD A through J: Coil Driver 1 through 10. Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM) and safety inspections. CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case. CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade. CHTIL: Cylinder Head Temperature Indicator Lamp. CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor thermistor. CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor. CKP: Crankshaft Position. Senses the position of the crankshaft. CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return. CL: Closed Loop. An operating condition or mode which enables operation based on sensor feedback. CMP: Camshaft Position. Indicates camshaft position. CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3457 CMS: Catalyst Monitor Sensor. Downstream H025. CMVSS: Canadian Motor Vehicle Safety Standards. CNG: Compressed Natural Gas. CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust emissions. CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of fuel. Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to increase voltage. Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the temperature of external and internal components stabilize. CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs generated during Continuous Memory Self-Test. Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM whenever the vehicle is operating. CPP: Clutch Pedal Position. Indicates clutch pedal position. CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the clutch pedal is depressed. CQIS: Common Quality Indicator System. CSE GND: Case Ground. CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to obtain the air/fuel mixture appropriate for closed throttle operation. CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer. Data Communications Link: A communication path between various in-vehicle electronic modules. Accessed by scan tools through the Data Link Connector (DLC). DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage measurement of ON time versus the full cycle period, expressed in percent. DCL: Data Communication Link. DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a distributor. Digital: Controls process information by switching the current or voltage ON and OFF. DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information. DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above the valves. DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument cluster. DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator Valve. DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other unwanted deposits. DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while the vehicle is operating. DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system. DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic System. DVOM: Digital Volt-Ohm Meter. E-85: Fuel containing 85% ethanol alcohol. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3458 EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an electric air pump. EAIRM: Electric Secondary Air Pump circuit Monitor. ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade. ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor thermistor. ECU: Electronic Control Unit. A module that handles the control strategy and monitors system inputs or outputs. EEC: Electronic Engine Control system. EEC-V: Fifth generation EEC system. EFT: Engine Fuel Temperature. EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade. EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor. EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade. EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor. EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into the combustion chamber. EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the monitor is complete. EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control. EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when energized by the PCM. EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is threaded into the bottom of the intake plenum. EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM. EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the EGR valve by varying the duty cycle to the regulator. EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the commanded output. EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists in the EGRV circuit. EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module (ICM) integrated into the PCM. EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition System. EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System. EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay operation or noisy generator contacts. EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new vehicles perform to design specifications. EPA: Environmental Protection Agency (U.S. Government). EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that requires the electronic storage of information. ESOF: Electronic Shift-on-the-Fly. EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere. EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the evaporative purge canister. EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists for the current commanded state. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3459 EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system canister from atmospheric pressure during the EVAP OBD II Monitor test. Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal which absorbs and holds fuel vapors. EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap Canister Purge Solenoid by the PCM. EVO: Electronic Variable Orifice. EWP: Electric Water Pump. Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed sensor. FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays OFF, LOW, or HIGH status. FC: Fan Control. FCS: Fuel Control Solenoid. FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed. FEAD: Front End Accessory Drive. FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming. FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that displays the % alcohol content in fuel. FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating the inferred alcohol content of fuel. FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is reliable or not. Displays a YES or NO. FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse width. FFV: Flexible Fuel Vehicle. FIFO: First In First Out. FILO: First In Last Out. FIM: Fuel Indicator Module. FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as a percentage. FLIV: Fuel Level Input Voltage. FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle function in the event of a PCM or EEC component failure. FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2. Fuel Pump (Modulated). Fuel pump duty cycle percentage. FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump. FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit. FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults. Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time. FRP: Fuel Rail Pressure. Based on FRP V. FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure Sensor. FSC: Fail-Safe Cooling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3460 FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or prevents Natural Gas flow to the fuel rail. FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or NO. FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit. FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts. FTP V: Fuel Tank Pressure Voltage. From the FTP transducer. FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump. FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update. FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1 (HEGO1). FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2 (HEGO2). FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP. Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and pressure from the fuel tank into the Evaporative Emission Control System. FWD: Front Wheel Drive. GEM: Generic Electronic Module. GEN: Generator. GENF: Generator Output Fault. GENFDC: Generator Field Control Output. GFS: Generator field signal monitor. GND: Ground. GPM: Grams Per Mile. Also known as Gallons Per Minute. GPS: Global Positioning Satellite. Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with California on-board diagnostics. GSS: Gear Select Solenoid. GVW: Gross Vehicle Weight. Hall Effect: A process where current is passed through a small slice of semi-conductor material and a magnetic field to produce a small voltage in the semi-conductor. Hard Fault: A fault currently present in the system. HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2. High Compression. HCF: Hydraulic Cooling Fan. HCFD: Hydraulic Cooling Fan Drive. HFC: Hydraulic Cooling Fan. HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit. HFP: High Fuel Pump. HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output commands with fixed values in response to internal Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3461 PCM malfunctions. HO: High Output. HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor. Provides information on rich or lean exhaust conditions to the PCM. Hot Soak: Period of time after an engine operates where localized combustion heat dissipates throughout the engine. HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the HO2S sensor. Hydrogen: Chemical symbol H. Highly flammable gas. Hz: Hertz. Cycles per second. IAC: Idle Air Control. Electrical control of throttle bypass air. IAT: Intake Air Temperature. IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor. IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on supercharged vehicles. IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor. IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit functions. ICM: Ignition Control Module. The module that controls the ignition system. IFDM: Integrated Fuel Delivery Module. IFS: Inertia Fuel Shutoff. IGN GND: Ignition Ground. Ignition: System used to provide high voltage spark for internal combustion engines. IGNKEY(IGKY): Ignition Key status. IGNSW (IGSW): Ignition Switch Position. IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the intake manifold. IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults. IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold. INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output from the PCM. Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders. Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion. Intercooler: See CAC. IPATS: Integrated Passive Anti-Theft System. ISO: international Standards Organization. KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even when the vehicle is not operating. KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM. Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied and the engine at rest. Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the engine running and the vehicle at rest. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3462 KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position. Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the combustion chamber of an engine. KOEC: Key On Engine Continuous. KOEO: Key On Engine off. KOER: Key On Engine Running. KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.). KPH: Kilometers Per Hour. KS: Knock Sensor. Detects engine knock. L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts. LEV: Low Emissions Vehicle. LFC: Low Fan Control. LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps. LIFO: Last In First Out. LILO: Last In Last Out. LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM. LOOP: indicates OPEN or CLOSED loop status. LPG: Liquefied Petroleum Gas. LPLR: Low Pressure Low Resistance fuel injector. M-V ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. M-85: Fuel containing 85% methanol alcohol. MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine. MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor. MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold. MFC: Medium Fan Control. MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled. MFP: Modulated Fuel Pump. Microprocessor: A digital processor on a chip which perform arithmetic and control logic. MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON." MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the crankshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3463 MON: Motor Octane Number. Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter. MSOF: Manual Shift-on-the-Fly. MY: Model Year. NA: Naturally Aspirated. Engine that is not supercharged or turbocharged. NAAO: North American Automotive Operations. NC: Normally Closed. NG: Natural Gas. A system capable of using natural gas for vehicle operation. NGS: New Generation STAR (Self-Test Automatic Readout) tester. NGVM: Natural Gas Vehicle Module. NO: Norm ally Open. NO(x): Oxides of Nitrogen. Formed at high combustion temperatures. NVH: Noise, Vibration, Harshness. A classification of vehicle concerns. OASIS: On-Line Automotive Service Information System. OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that monitors PCM input and output control signals. On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM. OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO. OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane. OEM: Original Equipment Manufacturer. OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the valves. OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp ON when engine oil temperature exceeds safe limits. Open Circuit: A circuit which does not provide a complete path for flow of current. OL: Open Loop. An operating condition based on instructions not modified by PCM feedback. O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen content in exhaust gasses. OSC: Output State Control. OSS: Output Shaft Speed. Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to ultraviolet radiation. Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines. PATS: Passive Anti-Theft System. PATSIL: Passive Anti-Theft System Indicator Light. PATSIN: Passive Anti-Theft System Receive Signal. PATSOUT: Passive Anti-Theft System Transmit Signal. PATSTRT: Passive Anti-Theft System Starter Relay Control Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3464 PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control) Processor. PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase vapors into the combustion chamber. PF: Purge Flow. Amount of fuel vapor burned in the engine. Photochemical: Term describing the action of light on air pollutants which results in creating smog. PID: Parameter Identifier. Identifies an address in PCM memory which contains operating information. Powertrain: Engine and transmission/transaxle components. Pressure - Absolute: A pressure referenced to a perfect vacuum. Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude. Sometimes called Barometric Pressure. Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer. Pressure - Differential: The pressure difference between two regions, such as between the intake manifold and atmospheric pressure. Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric pressure. PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization. Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP Sensor). PPM: Parts Per Million. A measure used in emission analysis. PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions. Protocol: A set of rules for the exchange of information on a network. PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed information. PSP: Power Steering Pressure. Indicates the pressure in the power steering system. PSP V: Power Steering Pressure Input Voltage. PTEC: Powertrain Electronic Controller. PTO: Power Take-Off. PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized. PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle. PWR GND: Power Ground. The main ground circuit in the EEC system. Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and Continuous Memory Self-Tests. Results are displayed as a series of DTCs. RABS: Rear Antilock Brake System. RAM: Random Access Memory. Memory into which information can be written as well as read. REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate at high temperatures. Regulator: Controls the alternator/generator field current to maintain proper battery charge. Contained within the PCM in smart charging applications. Relay: An electromechanical device in which connections in one circuit are opened or closed by changes in another circuit. REM: Rear Electronic Module. Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to improve idle quality and improve emissions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3465 RF: Radio Frequency. RFI: Radio Frequency Interference. RFS: Returnless Fuel System. RM: Relay Module. A module containing two or more relays. ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered. RON: Research Octane Number. Routine: A group of related tasks, such as a series of diagnostic tests. RPM: Revolutions Per Minute. RS: Reverse Switch. RTN: Return. A dedicated sensor ground circuit. RWD: Rear Wheel Drive. SAE: Society of Automotive Engineers. SBS: Supercharger Bypass Solenoid or its signal output from the PCM. SC: Supercharged or Supercharger. SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from the supercharger wastegate actuator to allow for maximum boost. SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger Bypass circuit. SCICP: Supercharger Intercooler Pump Control. SCICPF: Supercharger Intercooler Pump Control Fault. SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump. SCP: Standard Corporate Protocol. Self- Test: See Quick Test. Sensor: A device that detects the value or change in a physical quantity, such as temperature, pressure or flow rate, and converts the data into an electrical signal. SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is individually energized and timed relative to its cylinder intake event. Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic Interference (EMI). Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that intended. SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input during closed-loop operation. SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors. SIL: Shift Indicator Lamp. Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output circuit. SME: Society of Manufacturing Engineers. SOF: Shift-On-the-Fly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3466 SOHC: Single Overhead Cam. Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and pulled to a central position. ST: Scan Tool. A device that interfaces with and communicates information on a data link. Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7 parts of air for every 1 part of fuel. Switch: A device for making, breaking, or changing the connections in an electrical circuit. TA: Traction Assist. TACH: Tachometer. TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has an air bypass channel around the throttle plate. TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel slippage. 2. Turbocharger. TDC: Top Dead Center. Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration. Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors. Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees before (BTDC) or after (ATDC) top dead center of the compression stroke. TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to measure intake air temperature. TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate information for the PCM. TP V: Throttle Position Sensor Voltage. Transducer: A device that receives energy from one medium and transfers it to another. For example, thermal energy is converted to an electrical signal through a temperature probe. Transmissions/Transaxles: NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the end. TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns, procedures, or general service information. Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles while running. Also used during engine crank. Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure. Variable Reluctance: A process of passing a varying magnetic field through wire windings and inducing a voltage. VCT: Variable Camshaft Timing. VECI: Vehicle Emission Control Information label. VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced. Includes information about the year, model, engine, and plant origin of the vehicle. VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister. VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a digital (DVOM) display. VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare "Battery Voltage VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as a reference by certain sensors. WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain other operating conditions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3467 Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger. WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body. Zip Tube: Another name for "fresh air duct" or "air inlet duct". TRANSMISSIONS: NOTE: The transmission naming convention is as follows: ^ The first character, a number, is the number of forward gears. ^ The second character, either the letter "F" or "R," represents front (transaxle) or rear (transmission) wheel drive. ^ The next set of characters, a grouping of numbers, represents the design torque capacity of the transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle). ^ The last character, if used, is one of the following: ^ "E" for electronic shift ^ "N" for non-synchronous shift ^ "S" for synchronous shift ^ "W" for wide ratio ^ 4F27E: Also known as the FN Focus automatic transmission. ^ 4F44E: Formerly known as the CD4E. ^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E. ^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E. ^ 4R44E: Formerly known as A4LD for 3.0L applications. ^ 4R55E: Formerly known as A4LD for 4.0L applications. ^ 4R70W: Formerly known as AOD-E. ^ 4R100: Formerly known as E4OD. ^ 5R44E: Formerly known as A5LD for 3.0L applications. ^ 5R55E: Formerly known as A5LD for 4.0L applications. ^ 5R55N: Lincoln LS automatic transmission. ^ 5R55W: Wide-ratio truck transmission. ^ 4x4L: 4x4 Low. ^ A/T: Automatic Transmission. ^ CCS: Coast Clutch Solenoid. ^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists. ^ EPC: Electronic Pressure Control. ^ EPCV: Electronic Pressure Control Volts. ^ ESS: Electronic Shift Scheduling. ^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E. ^ M5OD: Manual 5-Speed transmission with overdrive (RWD). ^ M/T: Manual Transmission/Transaxle. ^ NPS: Neutral Pressure Switch or its signal input to the PCM. ^ OCS: Overdrive Cancel Switch. ^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft. ^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear Switch (NGS), and Transmission Switch Neutral (TSN). ^ REVERSE or REV: Transmission Reverse Switch Input. ^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual transmission/transaxle vehicles. ^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission. ^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and disengagement of the Torque Converter Clutch. ^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS) has been activated. ^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled transmissions. ^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between an engine and transmission/transaxle. ^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid. ^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same case. Front-wheel drive applications. ^ Transmission: A device which selectively increases or decreases the ratio of relative rotation between its input and output shafts. Rear-wheel drive applications. ^ TR: Transmission Range. The range in which the transmission is operating. ^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to the PCM on the transmission range selector position. ^ TR V: Transmission Range Voltage. ^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft. ^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is proportional to vehicle speed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3468 Catalytic Converter: Description and Operation Catalyst Efficiency Monitor - Federal Test Procedure Catalyst Efficiency Monitor - Federal Test Procedure The Catalyst Efficiency Monitor uses an oxygen sensor before and after the catalyst to infer the hydrocarbon efficiency based on oxygen storage capacity of the catalyst. Under normal, close-loop fuel conditions, high efficiency catalysts have significant oxygen storage. This makes the switching frequency of the rear Heated Oxygen Sensor (HO2S) very slow and reduces the amplitude of those switches as compared to the switching frequency and amplitude of the front HO2S. As the catalyst efficiency deteriorates, its ability to store oxygen declines. The post-catalyst or downstream HO2S signal begins to switch more rapidly with increasing amplitude, approaching the switching frequency and amplitude of the pre-catalyst or upstream HO2S. All applications utilize an FTP-based (Federal Test Procedure) catalyst monitor. This simply means that the catalyst monitor must run during a standard FTP emission test as opposed to the 20-second steady state catalyst monitor used in 1994 through some 1996 vehicles. Two slightly different versions of the catalyst monitor are used in the 2001 model year. Switch Ratio Method (1996 - 2001) 1. In order to assess catalyst oxygen storage, the monitor counts front and rear HO2S switches during part-throttle, close-loop fuel condition after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are accumulated in up to nine different air mass regions or cells although three air mass regions is typical. Rear switches are counted in a single cell for all air mass regions. When the required number of front switches has accumulated in each cell, the total number of rear switches is divided by the total number of front switches to compute a switch ratio. A switch ratio near 0.0 indicates high oxygen storage capacity, hence high HC efficiency. A switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual switch ratio exceeds a calibrated threshold switch ratio, the catalyst is considered failed. Inputs from Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) (warm engine), IAT (not extreme ambient temperatures), Mass Air Flow (MAF) (greater than minimum engine load), Vehicle Speed Sensor (VSS) (within vehicle speed widow) and Throttle Position (TP) (at part-throttle) are required to enable the Catalyst Efficiency Monitor. 2. The DTCs associated with this test are Diagnostic Trouble Code (DTC) P0420 (Bank 1) and P0430 (Bank 2). Because an Exponentially Weight Moving Average algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate the Malfunction Indicator Lamp (MIL) during normal customer driving. If Keep Alive Memory (KAM) is reset, a malfunction will illuminate the MIL in 2 drive cycles. Index Ratio Method (some 2001 and beyond) 1. In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches during part-throttle, closed-loop fuel conditions after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are accumulated in up to three different air mass regions or cells. While catalyst monitoring entry conditions are being met, the front and rear HO2S signal lengths are continually being calculated. When the required number of front switches has accumulated in each cell, the total signal length of the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index ratio. An index ratio near 0.0 indicates high oxygen storage capacity, hence high efficiency. A switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual index ratio exceeds the threshold index ratio, the catalyst is considered failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3469 Inputs from ECT or CHT (warm engine), IAT (not extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed widow) and TP (at part-throttle) are required to enable the Catalyst Efficiency Monitor. 2. The DTCs associated with this test are DTC P0420 (Bank 1) and P0430 (Bank 2). Because an Exponentially Weighted Moving Average algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate the MIL during normal customer driving. If KAM is reset, a malfunction will illuminate the MIL in 2 drive cycles. If the catalyst monitor does not complete during a particular driving cycle, the already accumulated switch/signal data is retained in Keep Alive Memory and is used during the next driving cycle to allow the catalyst monitor a better opportunity to complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3470 Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Catalyst and Exhaust System Overview The Catalytic Converter and Exhaust Systems (Figure 135) work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NO(x), and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. Generic Catalyst and Exhaust System Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides of Nitrogen (NO) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (TWC) converter contains either platinum (Pt) and Rhodium (Rh) or Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NO. The three-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3471 Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 3472 Catalytic Converter: Testing and Inspection For information regarding diagnosis of this system refer to Computers and Control Systems Diagnosis. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter-Dual Three-Way Catalytic Converter: Service and Repair Catalytic Converter-Dual Three-Way Catalytic Converter-Dual Three-Way Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the catalyst monitor sensor. 3. Remove the bolts and springs. 4. Loosen the LH nuts. 5. Loosen the RH nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 3475 6. Remove the nuts. 7. Detach the dual three-way converter from the isolator and remove the converter. 8. Remove the gaskets and, if necessary, the catalyst monitor sensor. ^ Discard the gaskets. 9. CAUTION: Tighten the exhaust component fasteners starting from the rear of the vehicle. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensor prior to installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 3476 Catalytic Converter: Service and Repair Dual Converter Y-Pipe Dual Converter Y-Pipe Removal and Installation 1. Remove the dual three-way catalytic converter. 2. Disconnect the heated oxygen sensors. 3. Remove the LH nuts. 4. Remove the RH nuts and remove the dual converter Y-pipe. 5. Remove the converter inlet gasket and, necessary, the heated oxygen sensors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 3477 ^ Discard the gasket. 6. CAUTION: Make sure that the dual converter Y-pipe to exhaust manifold nuts are tightened after the three-way catalytic converter is installed. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Torque Specifications Part 1 of 2 Part 2 of 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH Exhaust Manifold: Service and Repair LH Exhaust Manifold-LH Removal and Installation 1. Raise and support the vehicle. 2. Remove the bolts. 3. Lower the vehicle. 4. Disconnect the hoses from the differential pressure feedback (EGR) transducer. 5. Disconnect the EGR valve to exhaust manifold tube from the exhaust manifold. 6. Disconnect the EGR valve to exhaust manifold tube from the EGR valve and remove the EGR valve to exhaust manifold tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3483 7. Remove the LH exhaust manifold. 8. NOTE: Use new exhaust manifold gaskets and nuts. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3484 Exhaust Manifold: Service and Repair RH Exhaust Manifold-RH Removal 1. Raise and support the vehicle. 2. Remove the bolts. 3. Lower the vehicle. 4. Remove the RH exhaust manifold. 5. NOTE: Use new exhaust manifold gaskets and nuts. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair Heat Shield: Service and Repair Exhaust Heat Shield-Catalytic Converter and Muffler 1. Raise the vehicle. 2. Inspect the catalytic converter and muffler for loose or missing heat shields. 3. Install worm clamps for heat shields that are loose. ^ Use one of the following clamps: FOTZ-SA231-A or W705949-S300. ^ Trim off the excess ear of the worm clamp. 4. If the heat shields are missing, install new heat shields. If new heat shields are not available, install a new catalytic converter. 5. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler and Tailpipe Removal and Installation All vehicles 1. Raise and support the vehicle. 2. Remove the bolts and springs. Sport Trac vehicles 3. Remove the bolt and position the shock absorber out of the way. All vehicles 4. Remove the nut and position the right-hand stabilizer bar link out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 3491 5. Detach the tailpipe from the isolator. 6. Detach the muffler from the isolators and remove the muffler and tailpipe. 7. Remove the converter outlet pipe gasket. ^ Discard the gasket. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3503 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3504 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3505 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's Powertrain Control Module: Customer Interest Instrument Panel - `Buzz' At Low Engine RPM's Article No. 01-4-10 03/05/01 NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD AT IDLE OR LOW SPEED DRIVING FORD: 2001 EXPLORER ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a "buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control Module (PCM) resonating against the heat shield that is located inside the PCM. ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section 303-14 for removal procedure. 2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the Rotunda Squeak and Rattle Kit, part number 164-R4900. 3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the top surface of the module at the rear center of the module. This will dampen the buzz noise from the PCM outer case. (Figure 1). 4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure. 5. Test drive vehicle to verify that the noise is corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 3510 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 702000, 702100, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3516 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3517 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3522 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3523 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3524 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's Powertrain Control Module: All Technical Service Bulletins Instrument Panel - `Buzz' At Low Engine RPM's Article No. 01-4-10 03/05/01 NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD AT IDLE OR LOW SPEED DRIVING FORD: 2001 EXPLORER ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a "buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control Module (PCM) resonating against the heat shield that is located inside the PCM. ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section 303-14 for removal procedure. 2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the Rotunda Squeak and Rattle Kit, part number 164-R4900. 3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the top surface of the module at the rear center of the module. This will dampen the buzz noise from the PCM outer case. (Figure 1). 4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure. 5. Test drive vehicle to verify that the noise is corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 3529 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 702000, 702100, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3535 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3536 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3537 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3538 Powertrain Control Module: Diagrams Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3539 Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3540 Powertrain Control Module: Description and Operation POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic tool manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and is incapable of communicating. Remove and replace the old PCM. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 3543 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3547 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3548 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3549 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation SOLID STATE RELAY Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3558 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3559 Fuel Pump Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3560 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3564 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3565 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3566 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP) sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3575 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3576 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3577 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3578 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3582 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3583 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3584 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3588 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3592 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3593 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3597 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3598 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3599 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3604 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3608 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3609 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3613 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3614 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE SENSOR Intake Air Temperature (IAT) Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type (Figure 37), are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3615 Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3619 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3620 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3625 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3626 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3627 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3628 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3629 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3630 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3631 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3632 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3633 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3634 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3635 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3636 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3637 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3638 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3639 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3640 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3644 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3645 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3646 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3647 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3648 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3649 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3650 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3651 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3652 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3653 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3654 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3655 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3656 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 Heated Oxygen Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3661 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3662 Heated Oxygen Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3663 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3664 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor Monitor The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper output voltage. The following illustration shows that input is required from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. 1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper function. 2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the Output State Monitor (OSM) and by measuring the current going through the heater circuit. The HO2S Monitor DTCs can be categorized as follows: The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130, P1131, P1132, P1150, P1151 and P1152. The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153. The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151 and P0156. The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in on-demand is DTC P1127. The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129. 3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive drive cycles. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 3667 Heated Oxygen Sensor: Description and Operation PCM Inputs HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3668 Heated Oxygen Sensor: Service and Repair Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 2. Remove the Three Way Catalytic Converter (TWC). 3. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3669 Socket, Exhaust Gas Oxygen Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3678 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3679 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3680 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3681 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3682 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3688 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3689 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3690 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3691 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3692 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3697 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3698 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3699 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3705 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3706 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3707 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3708 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3709 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3710 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3711 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3712 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3716 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 3719 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3720 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3724 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3725 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3726 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3727 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3728 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3732 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3733 Vehicle Speed Sensor: Service and Repair Intermediate Shaft Speed (ISS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1. Remove the ISS sensor screw. 2. Remove the ISS sensor from the transmission. ^ Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the ISS sensor into the transmission. 2. Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3734 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3744 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3745 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3746 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3747 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3748 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3754 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3755 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3756 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3757 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3758 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3763 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3764 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3765 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3771 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3772 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3773 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3774 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3775 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3776 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3777 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3778 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3783 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3784 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3785 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3786 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE SENSOR Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations Inertia Fuel Shutoff Switch The Inertia Fuel Shutoff (IFS) switch is on the RH A-pillar lower trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3793 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3794 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3795 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3799 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 3802 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3803 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3808 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3809 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3810 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3814 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3815 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3816 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3822 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3823 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3827 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3828 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 3835 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3836 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3837 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Flexible Fuel Idle Speed: Specifications With Flexible Fuel With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Flexible Fuel > Page 3842 Idle Speed: Specifications Without Flexible Fuel With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3850 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3851 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3855 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 3868 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 3874 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3875 Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3876 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL TOOL(S) REMOVAL 1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 3. Disconnect the spark plug wires from the separators and remove the spark plug wires. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3877 Spark Plug Wire Remover Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................... 1.3-1.4 mm (0.052-0.056 in.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3882 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ...................................................... 20 Nm (15 ft lbs) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3883 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... .............................................................. AGRF22PG LH Original Spark Plug ..................................... ................................................................................................................................................... AGRF22P New Spark Plug (Either Side) ............................................................................................ ................................................................................. AGSF22PP Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3884 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3888 Compression Check: Testing and Inspection Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the powertrain control module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP) sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3899 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3900 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3901 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3902 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3906 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3907 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE SENSOR Intake Air Temperature (IAT) Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type (Figure 37), are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3908 Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3917 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3918 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3919 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3920 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3921 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3922 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3923 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3929 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3930 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3931 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3932 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3933 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3934 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3935 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3939 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3940 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3941 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3945 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Computers and Control Circuit Diode > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3952 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3953 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3957 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3958 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3959 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 Data Link Connector: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3993 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3994 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3995 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's Powertrain Control Module: Customer Interest Instrument Panel - `Buzz' At Low Engine RPM's Article No. 01-4-10 03/05/01 NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD AT IDLE OR LOW SPEED DRIVING FORD: 2001 EXPLORER ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a "buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control Module (PCM) resonating against the heat shield that is located inside the PCM. ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section 303-14 for removal procedure. 2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the Rotunda Squeak and Rattle Kit, part number 164-R4900. 3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the top surface of the module at the rear center of the module. This will dampen the buzz noise from the PCM outer case. (Figure 1). 4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure. 5. Test drive vehicle to verify that the noise is corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 4000 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 702000, 702100, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4006 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4007 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4012 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4013 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4014 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's Powertrain Control Module: All Technical Service Bulletins Instrument Panel - `Buzz' At Low Engine RPM's Article No. 01-4-10 03/05/01 NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD AT IDLE OR LOW SPEED DRIVING FORD: 2001 EXPLORER ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a "buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control Module (PCM) resonating against the heat shield that is located inside the PCM. ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section 303-14 for removal procedure. 2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the Rotunda Squeak and Rattle Kit, part number 164-R4900. 3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the top surface of the module at the rear center of the module. This will dampen the buzz noise from the PCM outer case. (Figure 1). 4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure. 5. Test drive vehicle to verify that the noise is corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 4019 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 702000, 702100, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4025 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4026 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4027 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4028 Powertrain Control Module: Diagrams Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4029 Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4030 Powertrain Control Module: Description and Operation POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic tool manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and is incapable of communicating. Remove and replace the old PCM. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 4033 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 4038 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pump Signal > Component Information > Description and Operation Fuel Pump Signal: Description and Operation FUEL PUMP MONITOR Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control The Fuel Pump Monitor (FPM) circuit is spliced into the Fuel Pump Power (FP PWR) circuit and is used by the PCM for diagnostic purposes. The PCM sources a low current voltage down the FPM circuit. With the fuel pump off, this voltage is pulled low by the path to ground through the fuel pump. With the fuel pump off and the FPM circuit low, the PCM can verify that the FPM circuit and the FP PWR circuit are complete from the FPM splice through the fuel pump to ground. This also confirms that the FP PWR or FPM circuits are not shorted to power. With the fuel pump on, voltage is now being supplied from the fuel pump relay to the FP PWR and FPM circuits. With the fuel pump on and the FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel pump relay to the FPM splice is complete. It can also verify that the fuel pump relay contacts are closed and there is a B+ supply to the fuel pump relay. Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals, Part 1 Fuel Pump Driver Module Duty Cycle Signals, Part 2 The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the Powertrain Control Module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 4045 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 4046 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4050 Idle Air Control Valve: Description and Operation IDLE AIR CONTROL VALVE Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4051 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4052 Idle Air Control Valve: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Disconnect the electrical connector, and remove the bolts and the Idle Air Control (IAC) valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Specifications General Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Module Communication Network: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4058 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4059 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4060 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4061 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4062 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4063 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4064 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 Module Communication Network: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 Module Communication Network: Electrical Diagrams DETAILED DIAGRAMS Diagram 418-00-00-1 Diagram 418-00-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Diagram 418-00-00-3 Diagram 418-00-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Diagram 418-00-00-5 RELATED DIAGRAM Diagram 501-12-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation Module Communication Network: Description and Operation The module communications network consists of the following items: ^ Generic Electronics Module (GEM) ^ Standard Corporate Protocol (SCP) communications network ^ International Standards Organization (ISO) communications network ^ Powertrain Control Module (PCM) ^ Anti-lock Brake Module (ABS) ^ Restraint Control Module (RCM) ^ Remote Anti-theft Personality (RAP)/central security module ^ Four-wheel Drive (4WD) control module (if equipped) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 4082 Module Communication Network: Description and Operation Principles and Operation The vehicle has two module communications networks. The Standard Corporate Protocol (SCP), which is an unshielded twisted pair cable (data bus plus, circuit 914 [TN/OG] and data bus minus, circuit 915 [PK/LB]); and the International Standards Organization (ISO) 9141 network which is a single wire (circuit 70 [LB/WH]). The diagnostic tool can connect to both networks through the Data Link Connector (DLC). This makes diagnosis and testing of these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel between the steering column and the radio. The SCP communication network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or voltage, or if some, but not all, termination resistors are lost. The ISO 9141 communication network does not permit inter-module communication. When the diagnostic tool communicates to modules on the ISO 9141 communication network, the diagnostic tool must ask for all information; the modules cannot initiate communications. Unlike the SCP, the ISO 9141 communication network will not function if the wire is shorted to ground or battery voltage. Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will fail. There is one module linked to the SCP communication network and five modules linked to the ISO 9141 communication network. The Powertrain Control Module (PCM) is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control and failure mode detection and storage. The Restraint Control Module (RCM) is on the ISO 9141 communication network. The RCM controls the deployment of the air bags based on sensor input. The Generic Electronic Module (GEM) is on the ISO 9141 communication network. The GEM controls a variety of systems: ^ windshield wipers ^ courtesy lamps ^ warning chimes ^ interior lamps ^ exterior lamps ^ power windows For additional GEM information, refer to Multifunction Electronic Control Module (General Module). The central security module (vehicles built after 7/24/2000) is on the ISO 9141 communication network. The remote anti-theft personality (RAP) module (vehicles built before 7/24/2000) is on the ISO 9141 communication network. The RAP/central security module controls the keyless remote entry of the vehicle. The Anti-lock Brake Control (ABS) module is on the ISO 9141 communication network. The ABS module controls the brake pressure to the four wheels to keep the vehicle under control while braking. The Four-wheel Drive (4WD) control module is on the ISO 9141 communications network. The 4WD module controls all four-wheel drive functions including the 4WDLOW and 4WDHIGH indicator lamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 4083 Module Communication Network: Description and Operation Principles of Operation Some modules must be programmed as part of the repair procedure. If this procedure is not followed the module will not function correctly and may set a number of Diagnostic Trouble Codes (DTCs), including B2477 or P1639, which indicate that some necessary data has not been programmed into the module. Modules that need programming should not be transferred between vehicles. In most cases the parameter values or settings are unique to that vehicle, and if not set correctly will cause malfunctions or faults. Some programmable parameters, such as belt minder on/off, can be changed from the factory setting at the customer's request. WDS will automatically attempt to retrieve the module configuration information from all modules, and from a backup location in the Powertrain Control Module (PCM) when Vehicle ID is carried out. If the module and the PCM do not contain correct information the diagnostic tool will either request "As Built" data or display a list of items that you will need to manually configure. The diagnostic tool will program the module based on the data you enter. There are three different methods that are used for module programming: ^ Programmable Module Installation (PMI) ^ calibration update ^ programmable parameters Some modules do not support all three methods. Programmable Module Installation (PMI) The programmable module installation (PMI) method is used when a new programmable module is installed on the vehicle. It is no longer necessary to command the diagnostic tool to gather module option content from the old module. The diagnostic tool automatically obtains any available module option content information from the old module during the Vehicle ID routine that runs when the diagnostic tool is initially connected to the vehicle. It is important that you connect WDS to the vehicle and allow it to identify the vehicle and obtain configuration data prior to removing any modules. Calibration Update Calibration update is used to install a new calibration and strategy into a module. The updates are usually issued to fix a concern in the module software and would normally be addressed by a Technical Service Bulletin (TSB). This method has been used by the PCM for several years. Other modules will be adopting this strategy as well. Programmable Parameters This method is used to configure parameters that can be modified in repair. These are typically at the preference of the customer. Not all features controlled by the module are listed in this configuration method. Refer to the Module Configuration Index for a list of features by system. If a module that has been modified using programmable parameters needs to be installed, the PMI procedure will maintain the parameters in their altered state if WDS is able to communicate with the old module during Vehicle ID. Otherwise you may need to use programmable parameters to return them to the altered state. Vehicle Identification (VID) Block Some PCMs contain a memory area called a vehicle identification (VID) block. The VID block is used to store backup data for each programmable module, as well as powertrain configuration information. If the diagnostic tool cannot retrieve module option content information from the suspect module, the diagnostic tool will attempt to extract backup information from the PCM's VID block. The PCM VID block contains the factory settings for the configurable modules unless the PCM is flashed with a new calibration, in which case some PCM parameters may be modified. As-Built Data Center The As-Built Data Center maintains a record of the vehicle configuration in a database. The vehicles VIN is necessary to obtain this information. The As-Built Data Center records the applicable module configurations stored in each module before the vehicle leaves the factory. The As-Built Data Center will always reflect the original build of the vehicle as it left the factory. Only contact the As-Built Data Center when directed to do so by the diagnostic tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network Module Communication Network: Testing and Inspection Module Communications Network Initial Inspection 1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical damage: VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse 17 (20A) ^ Damaged wiring harness ^ Loose or corroded connectors 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. If the diagnostic tool still does not communicate with the vehicle, go to Pinpoint Test I. See: Pinpoint Tests/Pinpoint Tests/Test I: No Module/Network Communication 4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) PC1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4086 A1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4087 A2 - A3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4088 B1 - B3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4089 B3 C1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4090 C2 - C3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4091 D1 - D3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4092 D3 E1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4093 E2 - E3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4094 F1 - F2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4095 F2 - F3 Test G: No Module/Network Communication - ISO 9141 Network Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4096 G1 - G3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4097 G3 - G4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4098 G5 - G6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4099 G7 - G8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4100 G9 - G11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4101 G11 - G12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4102 G13 - G14 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4103 G14 - G16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4104 G16 - G17 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4105 G17 - G18 Test H: No SCP Network Communication Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4106 H1 - H3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4107 H4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4108 H5 - H6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4109 H6 I1 - I2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4110 I2 - I4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4111 Symptom Chart, Part 1 Symptom Chart, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4112 Module Communication Network: Testing and Inspection Module Configuration Configurable Modules The vehicle contains the following modules that are configurable: ^ Anti-lock Brake (ABS) module (if equipped) ^ Generic Electronic Module (GEM) ^ Remote Anti-theft Personality (RAP)/central security module (if equipped) Initial Inspection 1. Visually inspect for obvious signs of electrical damage. Refer to the chart: VISUAL INSPECTION CHART Electrical ^ Wiring harness ^ Connectors Programmable Parameters Index Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 4113 Module Communication Network: Service and Repair Communication Circuit Wiring Repair Heat Gun SPECIAL TOOL(S) 1. Disconnect the battery ground cable. 2. Strip the wires. 3. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 4114 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair. ^ Overlap the heat shrink tube on both wires. 6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment Module Communication Network: Tools and Equipment Special Tool(s) Heat Gun Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 4117 Module Communication Network: Tools and Equipment Diagnostic Special Service Tool(S) Special Tool(s) Worldwide Diagnostic System Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4121 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4122 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4126 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4127 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4128 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4136 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4137 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4138 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4139 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4140 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4141 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4143 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4144 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4145 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4146 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4147 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4148 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4149 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4150 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4151 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 Heated Oxygen Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4171 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4172 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4173 Heated Oxygen Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4174 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4175 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor Monitor The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper output voltage. The following illustration shows that input is required from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. 1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper function. 2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the Output State Monitor (OSM) and by measuring the current going through the heater circuit. The HO2S Monitor DTCs can be categorized as follows: The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130, P1131, P1132, P1150, P1151 and P1152. The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153. The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151 and P0156. The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in on-demand is DTC P1127. The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129. 3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive drive cycles. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 4178 Heated Oxygen Sensor: Description and Operation PCM Inputs HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4179 Heated Oxygen Sensor: Service and Repair Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 2. Remove the Three Way Catalytic Converter (TWC). 3. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4180 Socket, Exhaust Gas Oxygen Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4189 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4190 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4191 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4192 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4193 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4199 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4200 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4201 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4202 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4203 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4208 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4209 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4210 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4216 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4217 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4218 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4219 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4220 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4221 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4222 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4223 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4233 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4234 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4235 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's Powertrain Control Module: Customer Interest Instrument Panel - `Buzz' At Low Engine RPM's Article No. 01-4-10 03/05/01 NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD AT IDLE OR LOW SPEED DRIVING FORD: 2001 EXPLORER ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a "buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control Module (PCM) resonating against the heat shield that is located inside the PCM. ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section 303-14 for removal procedure. 2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the Rotunda Squeak and Rattle Kit, part number 164-R4900. 3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the top surface of the module at the rear center of the module. This will dampen the buzz noise from the PCM outer case. (Figure 1). 4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure. 5. Test drive vehicle to verify that the noise is corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-10 > Mar > 01 > Instrument Panel - `Buzz' At Low Engine RPM's > Page 4240 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 702000, 702100, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4246 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4247 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 4252 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 4253 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 4254 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel `Buzz' At Low Engine RPM's Powertrain Control Module: All Technical Service Bulletins Instrument Panel - `Buzz' At Low Engine RPM's Article No. 01-4-10 03/05/01 NOISE - "BUZZ" COMING FROM CENTER OR RIGHT SIDE OF INSTRUMENT PANEL - HEARD AT IDLE OR LOW SPEED DRIVING FORD: 2001 EXPLORER ISSUE Some Sport and Sport Trac vehicles built between 7/1/2000 and 2/28/2001 may exhibit a "buzz" coming from the center or right side of the instrument panel at idle and/or low speed driving with rpm range between base idle and 1800 rpm. This may be caused by the Powertrain Control Module (PCM) resonating against the heat shield that is located inside the PCM. ACTION Verify buzz. Insulate the PCM from the heat shield with hard foam tape. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the PCM from the vehicle. Refer to the 2001 Explorer Workshop Manual, Section 303-14 for removal procedure. 2. Cut a piece of Urethane Tape (hard foam), Rotunda part number 164-R4902, to the following dimensions: 20 mm width, 3 mm thickness, and 45 mm length. The urethane tape is located in the Rotunda Squeak and Rattle Kit, part number 164-R4900. 3. Lay the PCM flat on a table. After removing the adhesive backing, place the foam tape on the top surface of the module at the rear center of the module. This will dampen the buzz noise from the PCM outer case. (Figure 1). 4. Reinstall the PCM. Refer to the Workshop Manual, Section 303-14 for installation procedure. 5. Test drive vehicle to verify that the noise is corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-4-10 > Mar > 01 > Instrument Panel `Buzz' At Low Engine RPM's > Page 4259 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 702000, 702100, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4265 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4266 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4267 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4268 Powertrain Control Module: Diagrams Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4269 Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4270 Powertrain Control Module: Description and Operation POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic tool manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and is incapable of communicating. Remove and replace the old PCM. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 4273 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4277 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4278 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4279 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP) sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4287 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4288 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4289 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4290 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4294 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4295 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4296 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 4300 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4304 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4305 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4309 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4310 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4311 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 4316 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 4320 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 4321 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4325 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4326 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE SENSOR Intake Air Temperature (IAT) Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type (Figure 37), are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4327 Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4331 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4332 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4337 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4338 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4339 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4340 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4341 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4342 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4343 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4344 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4345 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4346 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4347 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4348 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4349 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4350 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4351 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4352 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 Heated Oxygen Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 Heated Oxygen Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4376 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor Monitor The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper output voltage. The following illustration shows that input is required from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. 1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper function. 2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the Output State Monitor (OSM) and by measuring the current going through the heater circuit. The HO2S Monitor DTCs can be categorized as follows: The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130, P1131, P1132, P1150, P1151 and P1152. The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153. The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151 and P0156. The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in on-demand is DTC P1127. The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129. 3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive drive cycles. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 4379 Heated Oxygen Sensor: Description and Operation PCM Inputs HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4380 Heated Oxygen Sensor: Service and Repair Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 2. Remove the Three Way Catalytic Converter (TWC). 3. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4381 Socket, Exhaust Gas Oxygen Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4390 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4391 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4392 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4393 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4394 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4400 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4401 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4402 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4403 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4404 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4409 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4410 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4411 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4417 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4418 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4419 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4420 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4421 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4422 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4423 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4424 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4428 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 4431 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 4432 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4436 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4437 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4438 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4439 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4440 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4444 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4445 Vehicle Speed Sensor: Service and Repair Intermediate Shaft Speed (ISS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1. Remove the ISS sensor screw. 2. Remove the ISS sensor from the transmission. ^ Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the ISS sensor into the transmission. 2. Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4446 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4450 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 4453 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 4454 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4458 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4460 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4461 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4462 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 129). 1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and Crankshaft Position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Variable Cam Timing System HARDWARE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 4467 Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing Unit Assembly Variable Cam Timing (VCT) Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 4468 in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 4469 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation VARIABLE CAM TIMING (VCT) SOLENOID VALVE Variable Cam Timing (VCT) Solenoid Valve The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4476 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4477 Vehicle Speed Sensor: Service and Repair Intermediate Shaft Speed (ISS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1. Remove the ISS sensor screw. 2. Remove the ISS sensor from the transmission. ^ Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the ISS sensor into the transmission. 2. Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4478 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Description and Operation Air Diverter Solenoid: Description and Operation AIR BYPASS SOLENOID Secondary Air Injection Bypass Solenoid The secondary air injection bypass (AIR bypass) solenoid (Figure 122) is used by the PCM to control vacuum to the secondary air injection diverter (AIR diverter) valve. The AIR bypass solenoid is a normally closed solenoid. The AIR bypass solenoid also has a filtered vent feature to permit vacuum release. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation AIR DIVERTER VALVE Air Injection Diverter (AIR Diverter) Valve The secondary air injection diverter (AIR diverter) valve (Figure 123) is used with the electric AIR pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the electric AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the electric AIR pump is off, and vacuum is removed from the AIR diverter valve, the integral check valve disk is held on the seat and stops air from being drawn into the exhaust system and prevents the back flow of the exhaust into the Secondary Air Injection System. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation Air Injection Pump: Description and Operation ELECTRIC AIR PUMP Electric Air Pump The electric AIR pump (Figure 121) provides pressurized air to the Secondary Air Injection system. The electric AIR pump functions independently of rpm and is controlled by the PCM. The electric AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of system backpressure and system voltage. The inlet system of the AIR pump incorporates a non-serviceable filter and splash cap which helps to guard against dirt and water. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation SOLID STATE RELAY Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation Vacuum Check Valve: Description and Operation VACUUM CHECK VALVES Vacuum Check Valve A vacuum check valve (Figure 125) blocks air flow in one direction. It allows free air flow in the other direction. The check side of this valve will hold the highest vacuum registered on the vacuum side. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4500 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4501 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4502 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4503 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4504 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4505 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4506 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4507 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4508 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4509 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4510 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4511 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4512 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4513 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4514 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions Catalytic Converter: Description and Operation Acronyms and Definitions 2V - L ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. 2V: Two Valve engine configuration. 4V: Four Valve engine configuration. ABS: Anti-lock Brake System. A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by cooling and dehydrating the air. ACC: Air Conditioning Clutch. Indicates status of the A/C clutch. ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch. ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel. ACP: Air Conditioning Head Pressure or A/C cycling switch input state. ACPSW: Air Conditioning Pressure Switch. ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module (PCM) from the ACP switch or sensor. ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout control during heavy acceleration. A/D: Analog-to-Digital. Analog-to-Digital signal conversion. ADC: See ATDC. AFCM: Alternative Fuel Control Module. AIR: Secondary Air Injection. AIRB: Secondary Air Injection Bypass. Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system when the electric air pump is commanded on. AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System has been evaluated for OBD (On-Board Diagnostic) II purposes. Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry. AIRM: Secondary AIR pump monitor. Ambient Air Temperature: Temperature of the air surrounding an object. Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits of the signal. ARB: Air Resource Board. ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by Speed Control Command Switch (SCCS) inputs. ASCII: American Standard Code for Information Interchange. ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke. Measured in degrees of crankshaft rotation. AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale, rather than a digital display. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4517 AWD: All-Wheel Drive. BARO: Barometric Pressure. Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC solenoid disconnected. Base Timing: Spark advance in degrees before top dead center of the base engine without any control from the PCM or ICM. Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected directly to the battery. Compare "Vehicle Power (VPWR)." BAT TEMP: Battery Temperature. BJB: Battery Junction Box. BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness. BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be hydraulic or electric. BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the Brake Pedal Position (BPP) switch. BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by applying voltage to the control line. BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its stroke. Measured in degrees of crankshaft rotation. Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to module and to the DLC. CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of pressurized intake air. CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which govern fuel economy standards. CANVNT: Canister Vent Solenoid. Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine exhaust emissions. CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency Monitor has successfully completed. CCM: Comprehensive Component Monitor. CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various EEC components. CD A through J: Coil Driver 1 through 10. Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM) and safety inspections. CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case. CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade. CHTIL: Cylinder Head Temperature Indicator Lamp. CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor thermistor. CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor. CKP: Crankshaft Position. Senses the position of the crankshaft. CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return. CL: Closed Loop. An operating condition or mode which enables operation based on sensor feedback. CMP: Camshaft Position. Indicates camshaft position. CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4518 CMS: Catalyst Monitor Sensor. Downstream H025. CMVSS: Canadian Motor Vehicle Safety Standards. CNG: Compressed Natural Gas. CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust emissions. CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of fuel. Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to increase voltage. Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the temperature of external and internal components stabilize. CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs generated during Continuous Memory Self-Test. Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM whenever the vehicle is operating. CPP: Clutch Pedal Position. Indicates clutch pedal position. CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the clutch pedal is depressed. CQIS: Common Quality Indicator System. CSE GND: Case Ground. CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to obtain the air/fuel mixture appropriate for closed throttle operation. CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer. Data Communications Link: A communication path between various in-vehicle electronic modules. Accessed by scan tools through the Data Link Connector (DLC). DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage measurement of ON time versus the full cycle period, expressed in percent. DCL: Data Communication Link. DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a distributor. Digital: Controls process information by switching the current or voltage ON and OFF. DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information. DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above the valves. DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument cluster. DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator Valve. DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other unwanted deposits. DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while the vehicle is operating. DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system. DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic System. DVOM: Digital Volt-Ohm Meter. E-85: Fuel containing 85% ethanol alcohol. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4519 EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an electric air pump. EAIRM: Electric Secondary Air Pump circuit Monitor. ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade. ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor thermistor. ECU: Electronic Control Unit. A module that handles the control strategy and monitors system inputs or outputs. EEC: Electronic Engine Control system. EEC-V: Fifth generation EEC system. EFT: Engine Fuel Temperature. EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade. EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor. EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade. EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor. EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into the combustion chamber. EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the monitor is complete. EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control. EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when energized by the PCM. EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is threaded into the bottom of the intake plenum. EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM. EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the EGR valve by varying the duty cycle to the regulator. EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the commanded output. EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists in the EGRV circuit. EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module (ICM) integrated into the PCM. EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition System. EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System. EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay operation or noisy generator contacts. EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new vehicles perform to design specifications. EPA: Environmental Protection Agency (U.S. Government). EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that requires the electronic storage of information. ESOF: Electronic Shift-on-the-Fly. EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere. EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the evaporative purge canister. EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists for the current commanded state. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4520 EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system canister from atmospheric pressure during the EVAP OBD II Monitor test. Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal which absorbs and holds fuel vapors. EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap Canister Purge Solenoid by the PCM. EVO: Electronic Variable Orifice. EWP: Electric Water Pump. Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed sensor. FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays OFF, LOW, or HIGH status. FC: Fan Control. FCS: Fuel Control Solenoid. FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed. FEAD: Front End Accessory Drive. FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming. FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that displays the % alcohol content in fuel. FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating the inferred alcohol content of fuel. FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is reliable or not. Displays a YES or NO. FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse width. FFV: Flexible Fuel Vehicle. FIFO: First In First Out. FILO: First In Last Out. FIM: Fuel Indicator Module. FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as a percentage. FLIV: Fuel Level Input Voltage. FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle function in the event of a PCM or EEC component failure. FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2. Fuel Pump (Modulated). Fuel pump duty cycle percentage. FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump. FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit. FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults. Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time. FRP: Fuel Rail Pressure. Based on FRP V. FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure Sensor. FSC: Fail-Safe Cooling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4521 FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or prevents Natural Gas flow to the fuel rail. FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or NO. FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit. FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts. FTP V: Fuel Tank Pressure Voltage. From the FTP transducer. FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump. FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update. FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1 (HEGO1). FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2 (HEGO2). FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP. Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and pressure from the fuel tank into the Evaporative Emission Control System. FWD: Front Wheel Drive. GEM: Generic Electronic Module. GEN: Generator. GENF: Generator Output Fault. GENFDC: Generator Field Control Output. GFS: Generator field signal monitor. GND: Ground. GPM: Grams Per Mile. Also known as Gallons Per Minute. GPS: Global Positioning Satellite. Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with California on-board diagnostics. GSS: Gear Select Solenoid. GVW: Gross Vehicle Weight. Hall Effect: A process where current is passed through a small slice of semi-conductor material and a magnetic field to produce a small voltage in the semi-conductor. Hard Fault: A fault currently present in the system. HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2. High Compression. HCF: Hydraulic Cooling Fan. HCFD: Hydraulic Cooling Fan Drive. HFC: Hydraulic Cooling Fan. HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit. HFP: High Fuel Pump. HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output commands with fixed values in response to internal Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4522 PCM malfunctions. HO: High Output. HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor. Provides information on rich or lean exhaust conditions to the PCM. Hot Soak: Period of time after an engine operates where localized combustion heat dissipates throughout the engine. HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the HO2S sensor. Hydrogen: Chemical symbol H. Highly flammable gas. Hz: Hertz. Cycles per second. IAC: Idle Air Control. Electrical control of throttle bypass air. IAT: Intake Air Temperature. IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor. IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on supercharged vehicles. IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor. IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit functions. ICM: Ignition Control Module. The module that controls the ignition system. IFDM: Integrated Fuel Delivery Module. IFS: Inertia Fuel Shutoff. IGN GND: Ignition Ground. Ignition: System used to provide high voltage spark for internal combustion engines. IGNKEY(IGKY): Ignition Key status. IGNSW (IGSW): Ignition Switch Position. IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the intake manifold. IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults. IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold. INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output from the PCM. Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders. Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion. Intercooler: See CAC. IPATS: Integrated Passive Anti-Theft System. ISO: international Standards Organization. KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even when the vehicle is not operating. KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM. Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied and the engine at rest. Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the engine running and the vehicle at rest. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4523 KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position. Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the combustion chamber of an engine. KOEC: Key On Engine Continuous. KOEO: Key On Engine off. KOER: Key On Engine Running. KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.). KPH: Kilometers Per Hour. KS: Knock Sensor. Detects engine knock. L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts. LEV: Low Emissions Vehicle. LFC: Low Fan Control. LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps. LIFO: Last In First Out. LILO: Last In Last Out. LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM. LOOP: indicates OPEN or CLOSED loop status. LPG: Liquefied Petroleum Gas. LPLR: Low Pressure Low Resistance fuel injector. M-V ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. M-85: Fuel containing 85% methanol alcohol. MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine. MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor. MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold. MFC: Medium Fan Control. MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled. MFP: Modulated Fuel Pump. Microprocessor: A digital processor on a chip which perform arithmetic and control logic. MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON." MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the crankshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4524 MON: Motor Octane Number. Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter. MSOF: Manual Shift-on-the-Fly. MY: Model Year. NA: Naturally Aspirated. Engine that is not supercharged or turbocharged. NAAO: North American Automotive Operations. NC: Normally Closed. NG: Natural Gas. A system capable of using natural gas for vehicle operation. NGS: New Generation STAR (Self-Test Automatic Readout) tester. NGVM: Natural Gas Vehicle Module. NO: Norm ally Open. NO(x): Oxides of Nitrogen. Formed at high combustion temperatures. NVH: Noise, Vibration, Harshness. A classification of vehicle concerns. OASIS: On-Line Automotive Service Information System. OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that monitors PCM input and output control signals. On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM. OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO. OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane. OEM: Original Equipment Manufacturer. OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the valves. OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp ON when engine oil temperature exceeds safe limits. Open Circuit: A circuit which does not provide a complete path for flow of current. OL: Open Loop. An operating condition based on instructions not modified by PCM feedback. O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen content in exhaust gasses. OSC: Output State Control. OSS: Output Shaft Speed. Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to ultraviolet radiation. Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines. PATS: Passive Anti-Theft System. PATSIL: Passive Anti-Theft System Indicator Light. PATSIN: Passive Anti-Theft System Receive Signal. PATSOUT: Passive Anti-Theft System Transmit Signal. PATSTRT: Passive Anti-Theft System Starter Relay Control Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4525 PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control) Processor. PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase vapors into the combustion chamber. PF: Purge Flow. Amount of fuel vapor burned in the engine. Photochemical: Term describing the action of light on air pollutants which results in creating smog. PID: Parameter Identifier. Identifies an address in PCM memory which contains operating information. Powertrain: Engine and transmission/transaxle components. Pressure - Absolute: A pressure referenced to a perfect vacuum. Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude. Sometimes called Barometric Pressure. Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer. Pressure - Differential: The pressure difference between two regions, such as between the intake manifold and atmospheric pressure. Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric pressure. PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization. Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP Sensor). PPM: Parts Per Million. A measure used in emission analysis. PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions. Protocol: A set of rules for the exchange of information on a network. PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed information. PSP: Power Steering Pressure. Indicates the pressure in the power steering system. PSP V: Power Steering Pressure Input Voltage. PTEC: Powertrain Electronic Controller. PTO: Power Take-Off. PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized. PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle. PWR GND: Power Ground. The main ground circuit in the EEC system. Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and Continuous Memory Self-Tests. Results are displayed as a series of DTCs. RABS: Rear Antilock Brake System. RAM: Random Access Memory. Memory into which information can be written as well as read. REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate at high temperatures. Regulator: Controls the alternator/generator field current to maintain proper battery charge. Contained within the PCM in smart charging applications. Relay: An electromechanical device in which connections in one circuit are opened or closed by changes in another circuit. REM: Rear Electronic Module. Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to improve idle quality and improve emissions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4526 RF: Radio Frequency. RFI: Radio Frequency Interference. RFS: Returnless Fuel System. RM: Relay Module. A module containing two or more relays. ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered. RON: Research Octane Number. Routine: A group of related tasks, such as a series of diagnostic tests. RPM: Revolutions Per Minute. RS: Reverse Switch. RTN: Return. A dedicated sensor ground circuit. RWD: Rear Wheel Drive. SAE: Society of Automotive Engineers. SBS: Supercharger Bypass Solenoid or its signal output from the PCM. SC: Supercharged or Supercharger. SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from the supercharger wastegate actuator to allow for maximum boost. SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger Bypass circuit. SCICP: Supercharger Intercooler Pump Control. SCICPF: Supercharger Intercooler Pump Control Fault. SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump. SCP: Standard Corporate Protocol. Self- Test: See Quick Test. Sensor: A device that detects the value or change in a physical quantity, such as temperature, pressure or flow rate, and converts the data into an electrical signal. SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is individually energized and timed relative to its cylinder intake event. Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic Interference (EMI). Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that intended. SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input during closed-loop operation. SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors. SIL: Shift Indicator Lamp. Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output circuit. SME: Society of Manufacturing Engineers. SOF: Shift-On-the-Fly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4527 SOHC: Single Overhead Cam. Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and pulled to a central position. ST: Scan Tool. A device that interfaces with and communicates information on a data link. Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7 parts of air for every 1 part of fuel. Switch: A device for making, breaking, or changing the connections in an electrical circuit. TA: Traction Assist. TACH: Tachometer. TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has an air bypass channel around the throttle plate. TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel slippage. 2. Turbocharger. TDC: Top Dead Center. Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration. Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors. Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees before (BTDC) or after (ATDC) top dead center of the compression stroke. TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to measure intake air temperature. TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate information for the PCM. TP V: Throttle Position Sensor Voltage. Transducer: A device that receives energy from one medium and transfers it to another. For example, thermal energy is converted to an electrical signal through a temperature probe. Transmissions/Transaxles: NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the end. TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns, procedures, or general service information. Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles while running. Also used during engine crank. Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure. Variable Reluctance: A process of passing a varying magnetic field through wire windings and inducing a voltage. VCT: Variable Camshaft Timing. VECI: Vehicle Emission Control Information label. VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced. Includes information about the year, model, engine, and plant origin of the vehicle. VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister. VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a digital (DVOM) display. VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare "Battery Voltage VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as a reference by certain sensors. WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain other operating conditions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4528 Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger. WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body. Zip Tube: Another name for "fresh air duct" or "air inlet duct". TRANSMISSIONS: NOTE: The transmission naming convention is as follows: ^ The first character, a number, is the number of forward gears. ^ The second character, either the letter "F" or "R," represents front (transaxle) or rear (transmission) wheel drive. ^ The next set of characters, a grouping of numbers, represents the design torque capacity of the transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle). ^ The last character, if used, is one of the following: ^ "E" for electronic shift ^ "N" for non-synchronous shift ^ "S" for synchronous shift ^ "W" for wide ratio ^ 4F27E: Also known as the FN Focus automatic transmission. ^ 4F44E: Formerly known as the CD4E. ^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E. ^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E. ^ 4R44E: Formerly known as A4LD for 3.0L applications. ^ 4R55E: Formerly known as A4LD for 4.0L applications. ^ 4R70W: Formerly known as AOD-E. ^ 4R100: Formerly known as E4OD. ^ 5R44E: Formerly known as A5LD for 3.0L applications. ^ 5R55E: Formerly known as A5LD for 4.0L applications. ^ 5R55N: Lincoln LS automatic transmission. ^ 5R55W: Wide-ratio truck transmission. ^ 4x4L: 4x4 Low. ^ A/T: Automatic Transmission. ^ CCS: Coast Clutch Solenoid. ^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists. ^ EPC: Electronic Pressure Control. ^ EPCV: Electronic Pressure Control Volts. ^ ESS: Electronic Shift Scheduling. ^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E. ^ M5OD: Manual 5-Speed transmission with overdrive (RWD). ^ M/T: Manual Transmission/Transaxle. ^ NPS: Neutral Pressure Switch or its signal input to the PCM. ^ OCS: Overdrive Cancel Switch. ^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft. ^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear Switch (NGS), and Transmission Switch Neutral (TSN). ^ REVERSE or REV: Transmission Reverse Switch Input. ^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual transmission/transaxle vehicles. ^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission. ^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and disengagement of the Torque Converter Clutch. ^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS) has been activated. ^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled transmissions. ^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between an engine and transmission/transaxle. ^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid. ^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same case. Front-wheel drive applications. ^ Transmission: A device which selectively increases or decreases the ratio of relative rotation between its input and output shafts. Rear-wheel drive applications. ^ TR: Transmission Range. The range in which the transmission is operating. ^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to the PCM on the transmission range selector position. ^ TR V: Transmission Range Voltage. ^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft. ^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is proportional to vehicle speed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4529 Catalytic Converter: Description and Operation Catalyst Efficiency Monitor - Federal Test Procedure Catalyst Efficiency Monitor - Federal Test Procedure The Catalyst Efficiency Monitor uses an oxygen sensor before and after the catalyst to infer the hydrocarbon efficiency based on oxygen storage capacity of the catalyst. Under normal, close-loop fuel conditions, high efficiency catalysts have significant oxygen storage. This makes the switching frequency of the rear Heated Oxygen Sensor (HO2S) very slow and reduces the amplitude of those switches as compared to the switching frequency and amplitude of the front HO2S. As the catalyst efficiency deteriorates, its ability to store oxygen declines. The post-catalyst or downstream HO2S signal begins to switch more rapidly with increasing amplitude, approaching the switching frequency and amplitude of the pre-catalyst or upstream HO2S. All applications utilize an FTP-based (Federal Test Procedure) catalyst monitor. This simply means that the catalyst monitor must run during a standard FTP emission test as opposed to the 20-second steady state catalyst monitor used in 1994 through some 1996 vehicles. Two slightly different versions of the catalyst monitor are used in the 2001 model year. Switch Ratio Method (1996 - 2001) 1. In order to assess catalyst oxygen storage, the monitor counts front and rear HO2S switches during part-throttle, close-loop fuel condition after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are accumulated in up to nine different air mass regions or cells although three air mass regions is typical. Rear switches are counted in a single cell for all air mass regions. When the required number of front switches has accumulated in each cell, the total number of rear switches is divided by the total number of front switches to compute a switch ratio. A switch ratio near 0.0 indicates high oxygen storage capacity, hence high HC efficiency. A switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual switch ratio exceeds a calibrated threshold switch ratio, the catalyst is considered failed. Inputs from Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) (warm engine), IAT (not extreme ambient temperatures), Mass Air Flow (MAF) (greater than minimum engine load), Vehicle Speed Sensor (VSS) (within vehicle speed widow) and Throttle Position (TP) (at part-throttle) are required to enable the Catalyst Efficiency Monitor. 2. The DTCs associated with this test are Diagnostic Trouble Code (DTC) P0420 (Bank 1) and P0430 (Bank 2). Because an Exponentially Weight Moving Average algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate the Malfunction Indicator Lamp (MIL) during normal customer driving. If Keep Alive Memory (KAM) is reset, a malfunction will illuminate the MIL in 2 drive cycles. Index Ratio Method (some 2001 and beyond) 1. In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches during part-throttle, closed-loop fuel conditions after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are accumulated in up to three different air mass regions or cells. While catalyst monitoring entry conditions are being met, the front and rear HO2S signal lengths are continually being calculated. When the required number of front switches has accumulated in each cell, the total signal length of the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index ratio. An index ratio near 0.0 indicates high oxygen storage capacity, hence high efficiency. A switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual index ratio exceeds the threshold index ratio, the catalyst is considered failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4530 Inputs from ECT or CHT (warm engine), IAT (not extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed widow) and TP (at part-throttle) are required to enable the Catalyst Efficiency Monitor. 2. The DTCs associated with this test are DTC P0420 (Bank 1) and P0430 (Bank 2). Because an Exponentially Weighted Moving Average algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate the MIL during normal customer driving. If KAM is reset, a malfunction will illuminate the MIL in 2 drive cycles. If the catalyst monitor does not complete during a particular driving cycle, the already accumulated switch/signal data is retained in Keep Alive Memory and is used during the next driving cycle to allow the catalyst monitor a better opportunity to complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4531 Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Catalyst and Exhaust System Overview The Catalytic Converter and Exhaust Systems (Figure 135) work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NO(x), and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. Generic Catalyst and Exhaust System Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides of Nitrogen (NO) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (TWC) converter contains either platinum (Pt) and Rhodium (Rh) or Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NO. The three-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4532 Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 4533 Catalytic Converter: Testing and Inspection For information regarding diagnosis of this system refer to Computers and Control Systems Diagnosis. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter-Dual Three-Way Catalytic Converter: Service and Repair Catalytic Converter-Dual Three-Way Catalytic Converter-Dual Three-Way Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the catalyst monitor sensor. 3. Remove the bolts and springs. 4. Loosen the LH nuts. 5. Loosen the RH nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 4536 6. Remove the nuts. 7. Detach the dual three-way converter from the isolator and remove the converter. 8. Remove the gaskets and, if necessary, the catalyst monitor sensor. ^ Discard the gaskets. 9. CAUTION: Tighten the exhaust component fasteners starting from the rear of the vehicle. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensor prior to installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 4537 Catalytic Converter: Service and Repair Dual Converter Y-Pipe Dual Converter Y-Pipe Removal and Installation 1. Remove the dual three-way catalytic converter. 2. Disconnect the heated oxygen sensors. 3. Remove the LH nuts. 4. Remove the RH nuts and remove the dual converter Y-pipe. 5. Remove the converter inlet gasket and, necessary, the heated oxygen sensors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter-Dual Three-Way > Page 4538 ^ Discard the gasket. 6. CAUTION: Make sure that the dual converter Y-pipe to exhaust manifold nuts are tightened after the three-way catalytic converter is installed. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 4543 Canister Purge Control Valve: Service Precautions WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 4544 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve EVAP Canister Purge Valve EVAP Canister Purge Valve The EVAP canister purge valve (Figure 95) and (Figure 96) is the part of the Enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is normally closed valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 4545 Canister Purge Control Valve: Service and Repair REMOVAL 1. Remove the battery tray. 2. Disconnect the tubes. 1 Disconnect the electrical connector. 2 Disconnect the tubes from the Evaporative Emission (EVAP) canister purge valve. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the EVAP canister purge valve and bracket. ^ Remove the bolt. 4. Remove the EVAP canister purge valve. 1 Disconnect the vacuum line from the EVAP canister purge valve. 2 Remove the EVAP canister purge valve. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions Evaporative Canister Filter: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions > Page 4549 Evaporative Canister Filter: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions > Page 4550 6. Disconnect the canister vent solenoid hose assembly. 7. Remove the evaporative emission dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission system. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service Precautions Evaporative Emission Control Canister: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service Precautions > Page 4554 Evaporative Emission Control Canister: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service Precautions > Page 4555 6. Remove the canister vent solenoid and the evaporative emission tube. 1 Disconnect the canister vent solenoid hose. 2 Remove the canister vent solenoid. 3 Remove the evaporative emission canister purge sleeve. 4 Remove the evaporative emission tube. 7. Remove the evaporative emission canister from the evaporative emission canister bracket. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL(R) O-ring Seal Lubricant or equivalent meeting Ford specification ESE-M99B144-B. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service Precautions Evaporative Emissions Hose: Service Precautions WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service Precautions > Page 4559 Evaporative Emissions Hose: Service and Repair DISCONNECT 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. CONNECT 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Service and Repair Evaporative System Service Port: Service and Repair REMOVAL 1. Remove the clip. 2. Disconnect the hoses. 3. Remove the test port assembly. ^ Disconnect the fitting. ^ Remove the test port assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Description and Operation Leak Detection Solenoid: Description and Operation Canister Vent Solenoid Typical Canister Vent (CV) Solenoid During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid (Figure 99) seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the monitor run. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information Leak Detection Valve: Technician Safety Information WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information > Page 4571 Leak Detection Valve: Vehicle Damage Warnings CAUTION: The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service Precautions > Page 4572 Leak Detection Valve: Service and Repair REMOVAL 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the EVAP canister. 3. Remove the canister vent solenoid. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the EVAP system. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service Precautions > Page 4573 Worldwide Diagnostic System Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Service Precautions Liquid Vapor Separator: Service Precautions WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Service Precautions > Page 4577 Liquid Vapor Separator: Service and Repair REMOVAL 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Lower the fuel tank. 3. Remove the EVAP canister tube from the fuel vapor vent valve. 4. Remove the fuel vapor vent valve. ^ Press down and rotate the fuel vapor vent valve counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 4582 EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR VACUUM REGULATOR SOLENOID EGR Vacuum Regulator Solenoid Test Graph EGR Vacuum Regulator Solenoid Data Chart The EGR vacuum regulator solenoid (Figure 88) is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 4583 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid. 1 Disconnect the electrical connector. 2 Disconnect the vacuum lines. 3 Remove the nut. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation EGR Tube: Description and Operation ORIFICE TUBE ASSEMBLY Orifice Tube Assembly The orifice tube assembly (Figure 90) is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and two pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation > Page 4587 EGR Tube: Service and Repair REMOVAL 1. Remove the lower Exhaust Gas Recirculation (EGR) valve tube. 1 Disconnect the tube fittings. 2 Disconnect the differential pressure feedback EGR hoses. 3 Remove the tube. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR EGR Valve: Description and Operation Differential Pressure Feedback EGR EXHAUST GAS RECIRCULATION VALVE EGR Valve Test Graph The EGR valve (Figure 89) in the Differential Pressure Feedback EGR system is a conventional, vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing service specifications on flow rate is impractical. The on-board diagnostic system monitors the EGR valve function and triggers a Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the field diagnostic procedures. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR > Page 4592 EGR Valve: Description and Operation Electric Motor EGR System (EEGR) ELECTRIC EGR VALVE Electric EGR Motor/Valve Assembly Electric EGR The electric EGR valve (Figure 92) and (Figure 93) is a water cooled motor/valve assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the the EGR valve. The position of the valve determines the rate of EGR. The built in spring works to close the valve (against the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR > Page 4593 motor opening force). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 4594 EGR Valve: Service and Repair REMOVAL 1. Disconnect the Exhaust Gas Recirculation (EGR) valve. ^ Disconnect the vacuum line. ^ Disconnect the EGR valve tube fitting. 2. Remove the EGR valve bolts and the EGR valve. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. ^ Carefully clean the EGR valve sealing surfaces. ^ Install a new EGR valve gasket. NOTE: The EGR valve sealing surfaces are soft metals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4603 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4604 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4605 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4606 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4607 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4613 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4614 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4615 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4616 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4617 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4622 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4623 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4624 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4630 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4631 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4632 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4633 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4634 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4635 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4636 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4637 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair Positive Crankcase Ventilation Valve: Service and Repair REMOVAL 1. Remove the vacuum hose. 2. Remove the Positive Crankcase Ventilation (PCV) valve. 1 Disconnect the coolant hoses from the PCV valve. 2 Unlock and remove the PCV valve from the valve cover. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation SOLID STATE RELAY Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4655 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4656 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4657 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4658 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4659 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4665 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4666 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4667 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4668 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4669 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4674 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4675 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4676 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4682 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4683 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4684 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4685 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4686 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4687 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4688 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4689 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4696 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4697 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4698 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4702 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4703 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With Flexible Fuel Idle Speed: Specifications With Flexible Fuel With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With Flexible Fuel > Page 4708 Idle Speed: Specifications Without Flexible Fuel With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4712 Accelerator Pedal: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide open throttle position. Hesitation or binding should not be experienced at any portion of the accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable or interfere with the accelerator pedal and shaft. The acceleration control consists of an accelerator pedal and cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview NOTE: Care should be exercised when carrying out repair on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause binding. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4715 Accelerator Pedal: Symptom Related Diagnostic Procedures Symptom Chart, Part 1 Symptom Chart, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Page 4716 Accelerator Pedal: Service and Repair REMOVAL 1. Disconnect the cable from the accelerator pedal. 2. Remove the screw and the accelerator pedal. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4723 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4724 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4725 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4726 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4735 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4736 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4737 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4738 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4739 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4740 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4741 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4747 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4748 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4749 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4750 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4751 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4752 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4753 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4762 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4763 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4764 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4765 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4766 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4772 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4773 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4774 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4775 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4776 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4777 Fuel Filler Cap: Description and Operation FUEL FILLER CAP Fuel Filler Cap The fuel filler cap (Figure 100) is used to prevent fuel spill and close the evaporative emission/fuel system to atmosphere. Some vehicles may have a Fuel Cap Off Indicator Lamp (FCIL) in the instrument cluster which will illuminate when there is a failure in the vapor management system that may be due to the fuel filler cap not being sealed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4782 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4783 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair Fuel Injector Wiring Harness: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the six fuel injector electrical connectors. NOTE: One connector is shown, the other five are similar. 3. Remove the bolt. 4. Disconnect the ignition coil electrical connector. 5. Disconnect the radio interference capacitor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4788 6. Disconnect the engine coolant temperature sensor electrical connector and the water temperature indicator sender unit connector. 7. Disconnect the differential pressure feedback transducer electrical connector and the Camshaft Position (CMP) sensor electrical connector. 8. Remove the drive belt tensioner. 9. Disconnect the generator wiring and position the wiring aside. 10. Remove the generator mounting bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4789 11. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 12. Remove the wiring anchors and position the wiring aside. 13. Raise and support the vehicle. 14. Disconnect the transmission portion of the wiring harness. 1 Disconnect the RH and LH Heated Oxygen Sensor (HO2S) connectors. 2 Disconnect the transmission control connector. 3 Disconnect the Output Shaft Speed (OSS) sensor connector. 4 Disconnect the digital Transmission Range (TR) sensor connector. 15. Disconnect the catalyst monitor sensor electrical connector. 16. Release the transmission/transfer case portion of the wiring harness from any routing clips or pushpins. 17. Route the transmission/transfer case portion of the wiring harness to the top of the engine. 18. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4790 19. Remove the wiring harness from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Disconnect Tool SPECIAL TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. See: Fuel Filter/Fuel Pressure Release 2. Disconnect the safety clip from the male hose. 3. Install the Fuel Line Disconnect Tool and push it into the fitting. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4796 4. Separate the fittings. ^ Inspect for damage. ^ Clean the fittings. CONNECT 1. Align the tube to the fitting and push until you hear a click. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4797 Fuel Line Coupler: Service and Repair R-Clip Fittings DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Relieve the fuel pressure. See: Fuel Filter/Fuel Pressure Release 2. Remove the shipping tab by bending downward. 3. Spread the R-clip legs and push the clip into the fitting. 4. Separate the fitting from the tube. CONNECT 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of Super Premium SAE 5W-30 XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to the male tube end. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4798 3. Insert the R-clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube into the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4799 Fuel Line Coupler: Service and Repair Spring Lock Couplings Special Tool(s) SPECIAL TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. See: Fuel Filter/Fuel Pressure Release 2. Remove the safety clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4800 3. Install the Spring Lock Coupler Tool. 4. Close and push the Spring Lock Coupler Tool into the open side of the cage. 5. Separate the coupler. 6. Remove the Spring Lock Coupler Tool. CONNECT 1. Inspect and clean both the coupling ends. Lubricate the O-ring seals with Super Premium SAE 5W-30 XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4801 2. Connect the coupler by inserting the male end into the female end of the coupler. Push the coupler together until the garter spring is engaged. 3. Pull on the coupler to make sure it is fully engaged. 4. Install the safety clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 4802 Fuel Line Coupler: Tools and Equipment Special Tool(s) Fuel Line Disconnect Tool Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations FUEL PUMP MODULE Fuel Pump Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4806 Fuel Pump Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4807 Mechanical Returnless Fuel Pump Module (FPM) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4808 Electronic Returnless Fuel Pump Module (FPM) The Fuel Pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4809 Fuel Pressure Regulator: Description and Operation FUEL PUMP MODULE Fuel Pump Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4810 Fuel Pump Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4811 Mechanical Returnless Fuel Pump Module (FPM) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4812 Electronic Returnless Fuel Pump Module (FPM) The Fuel Pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE SENSOR Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4820 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4821 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4822 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Pulsation Damper: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information > Page 4827 Fuel Pressure Pulsation Damper: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 4828 Fuel Pressure Pulsation Damper: Description and Operation FUEL RAIL PULSE DAMPER Pulse Damper The fuel rail pulse damper (Figure 71) located on the fuel rail reduces fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail pressure.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 4829 Fuel Pressure Pulsation Damper: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the fuel pulse damper and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4836 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4837 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4838 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4842 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4843 Fuel Pump Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4844 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information Fuel Rail: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information > Page 4849 Fuel Rail: Vehicle Damage Warnings CAUTION: ^ If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the supply manifold. ^ Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4850 Fuel Rail: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the supply manifold. 1. Remove the intake manifold. 2. Disconnect the fuel line. 3. Disconnect the six fuel injector electrical connectors. NOTE: One connector is shown, the other five are similar. 4. Remove the four bolts from the fuel line. 5. Disconnect the fuel pulse damper vacuum hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4851 6. Remove the fuel injection supply manifold. 7. Remove the fuel injectors. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: ^ Lubricate the new O-ring seals with clean engine oil. ^ Use new fasteners to attach the fuel line. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment Fuel Supply Line: Tools and Equipment 3/8" Fuel Line Remover AST tool# 8013 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 4855 Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit. - For R and R of Fuel and Feed Lines - Quick line removal - Gold-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: 8110 - 10-Pc. Line Disconnect Set Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 4856 8107 - 7-Piece Line Disconnect Set Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4866 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4867 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4868 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4869 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4870 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4876 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4877 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4878 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4879 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4880 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Hose: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Hose: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 4886 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Hose: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 4892 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4893 Fuel Filler Hose: Service and Repair REMOVAL 1. Remove the fuel tank filler cap. NOTE: Fuel tank filler pipe may contain fuel. 2. Remove the screws. 3. Remove the fuel tank filler pipe and the vent hose from the fuel tank and remove the fuel tank filler pipe. INSTALLATION 1. Install the fuel tank filler pipe and the vent hose. 1 Orient the clamp bonding patch with the top of the fuel tank. 2 Tighten the hose clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4894 2. Install the three fuel tank filler pipe screws. 3. Install the fuel tank filler cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4903 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4904 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4905 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4906 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4907 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4913 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4914 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4915 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4916 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4917 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair Fuel Tank Mounting Straps: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Use a suitable jack to support the fuel tank. 3. Remove the bolt and the fuel tank support strap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Tank Unit: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4927 Idle Air Control Valve: Description and Operation IDLE AIR CONTROL VALVE Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4928 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4929 Idle Air Control Valve: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Disconnect the electrical connector, and remove the bolts and the Idle Air Control (IAC) valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations Inertia Fuel Shutoff Switch The Inertia Fuel Shutoff (IFS) switch is on the RH A-pillar lower trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4933 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4934 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4935 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair REMOVAL 1. Remove the engine appearance cover bolts. 2. Remove the air cleaner outlet tube. 1 Unclip the wire harness. 2 Disconnect the crankcase ventilation tube. 3 Loosen the air cleaner outlet tube clamps and remove the air cleaner outlet tube. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4942 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4943 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4944 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4949 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4950 Fuel Pump Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4951 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4955 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4956 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4957 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4962 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4963 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4964 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4965 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE SENSOR Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations Inertia Fuel Shutoff Switch The Inertia Fuel Shutoff (IFS) switch is on the RH A-pillar lower trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4972 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4973 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4974 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4978 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 4981 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 4982 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information Throttle Body: Technician Safety Information WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information > Page 4987 Throttle Body: Vehicle Damage Warnings CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body may occur. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Housing Throttle Body: Description and Operation Throttle Body Housing THROTTLE BODY HOUSING The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Housing > Page 4990 Throttle Body: Description and Operation Throttle Body System Overview THROTTLE BODY SYSTEM OVERVIEW The throttle body system meters air to the engine during idle, part throttle, and Wide Open Throttle (WOT) conditions. The throttle body system consists of an Idle Air Control (IAC) valve assembly, idle air orifice, single or dual bores with butterfly valve throttle plates and a Throttle Position (TP) sensor. One other source of idle air flow is the Positive Crankcase Ventilation (PCV) system. The combined idle air flow (from idle air orifice IAC flow and PCV flow) is measured by the MAF sensor on all applications. During idle, the throttle body assembly provides a set amount of air flow to the engine through the idle air passage and PCV valve. The IAC valve assembly provides additional air when commanded by the Powertrain Control Module (PCM) to maintain the proper engine idle speed under varying conditions. The IAC valve assembly mounts directly to the throttle body assembly in most applications, but is remote-mounted to the intake manifold in some applications. Idle speed is controlled by the PCM and cannot be adjusted. NOTE: The traditional idle air adjust procedure as well as throttle return screw are no longer used on OBD II applications. Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle plate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. Some throttle body applications provide an air supply channel upstream of the throttle plate to provide fresh air to the Positive Crankcase Ventilation (PCV) or IAC systems. Other throttle body applications provide individual vacuum taps downstream of the throttle plate for PCV return, Exhaust Gas Recirculation (EGR), Evaporative Emission (EVAP), and miscellaneous control signals. Throttle Body System Hardware The major components of the throttle body assembly include the TP sensor, IAC valve assembly, and throttle body housing assembly. Throttle Position Sensor The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Housing > Page 4991 Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Housing > Page 4992 ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Throttle Body Housing The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Typical Attention Decal Locations Features of the Throttle Body Assembly include: 1. Idle Air Control (IAC) valve assembly mounted directly to the throttle body assembly (some vehicles). 2. A pre-set stop to locate the WOT position. 3. An air supply channel upstream of the throttle plate to provide fresh air to the PCV system (some vehicles only). 4. Individual vacuum taps for PCV, EGR, Evaporative Emission (EVAP) and miscellaneous control signals (some vehicles only). 5. PCV air return (it applicable). 6. A throttle body-mounted Throttle Position (TP) sensor. 7. A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to engine intake sludge accumulation. These throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal (Figure 116) advising not to clean. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Page 4993 Throttle Body: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body may occur. 1. Remove the air cleaner outlet tube. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Disconnect the accelerator cable and the speed control cable (if equipped). 4. Remove the throttle body. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Customer Interest for Throttle Cable/Linkage: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Throttle Cable/Linkage: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Customer Interest for Throttle Cable/Linkage: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 5002 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Throttle Cable/Linkage: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 5008 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 5009 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 5010 Throttle Cable/Linkage: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide open throttle position. Hesitation or binding should not be experienced at any portion of the accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable or interfere with the accelerator pedal and shaft. The acceleration control consists of an accelerator pedal and cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 5011 Throttle Cable/Linkage: Testing and Inspection For further information regarding the diagnosis of this system, please refer to Accelerator Pedal; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 5012 Throttle Cable/Linkage: Service and Repair REMOVAL 1. Disconnect the cable from the accelerator pedal. 2. Collapse the clips at the dash panel and push the cable through the dash panel into the engine compartment. 3. Remove the bolts and the accelerator cable snow shield. 4. Disconnect the cable from the throttle body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 5013 5. Remove the accelerator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5017 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 5020 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 5021 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 5026 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5034 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5035 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5036 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5040 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5041 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5042 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 5051 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 5057 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 5058 Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 5059 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL TOOL(S) REMOVAL 1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 3. Disconnect the spark plug wires from the separators and remove the spark plug wires. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 5060 Spark Plug Wire Remover Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Mechanical Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5065 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5066 Ignition Coil: Service Precautions CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5067 Ignition Coil: Description and Operation Coil Pack Horizontal Connector Six Tower Coil Pack Series 5 Six Tower Coil Pack Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5068 Four - Tower Coil Packs Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5069 Series 5 Four Tower Coil Pack Coil packs come in four tower, Series 5 four tower, six-tower horizontal connector and Series 5 Six tower models. Two adjacent coil towers share a common coil and are called a matched pair. For six-tower coil pack (six cylinder) applications the matched pairs are 1 and 5, 2 and 6, and 3 and 4 (Figure 56)and (Figure 57). For four-tower coil pack (four cylinder) applications the matched pairs are 1 and 4, and 2 and 3 (Figure 58) and (Figure 59). When the coil is fired by the PCM, spark is delivered through the matched pair towers to their respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the situation is reversed. The next pair of spark plugs fire according to the engine firing order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5070 Ignition Coil: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connector. 3. Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. 4. Remove the bolts and the ignition coil. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 5074 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 5075 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5080 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5081 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5082 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5086 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5087 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5088 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5094 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5095 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5099 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5100 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................... 1.3-1.4 mm (0.052-0.056 in.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 5105 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ...................................................... 20 Nm (15 ft lbs) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5106 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... .............................................................. AGRF22PG LH Original Spark Plug ..................................... ................................................................................................................................................... AGRF22P New Spark Plug (Either Side) ............................................................................................ ................................................................................. AGSF22PP Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5107 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5114 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5115 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5116 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5139 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift strategy. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected, or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5140 Pressure Regulating Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5141 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5142 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5143 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5147 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1. Remove the screws and position the hood release handle out of the way. 2. Remove the two screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5148 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid Clamp Screws 53 - 71 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5152 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5153 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5154 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5155 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5178 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5179 Shift Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5180 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5181 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5182 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5186 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5187 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5188 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5211 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5212 Torque Converter Clutch Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5213 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5214 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5215 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5226 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5227 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1. Remove the cover. 2. Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5231 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5232 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5233 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5234 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5235 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5241 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5242 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5247 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5248 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5249 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5250 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 Transmission Speed Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 Transmission Speed Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5266 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5267 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5268 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5294 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5301 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5302 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 5305 Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 5306 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 5307 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 5308 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming Technical Service Bulletin # 00B58 Date: 001201 Information 00B58 OWNER NOTIFICATION PROGRAM Certain 2001 Model Year Explorer Sport Trac 4x2 Vehicles - Powertrain Calibration Update Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5317 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5318 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT Promptly correct all affected vehicles on the enclosed list and other eligible vehicles which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Refunds do not apply to the program. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5319 LABOR ALLOWANCES Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR SPORT TRAC VEHICLES SERVICE PROCEDURE 1. Reprogram the Powertrain Control Module (PCM) with the latest calibration using one of the following two (2) methods: ^ Worldwide Diagnostic System (WDS). Use WDS CD-ROM B10 release (or subsequent release if applicable) available via Fordstar, or for Non-Fordstar dealers available at: http://www.fordtechservice.com/vdirs/wds ^ Service Bay Technical System (SBTS) and the New Generation Star (NGS) Tester with Rotunda Flash Cable (007-00531) and Rotunda Flash Card (007-00532). Use the October release CD-ROM (or subsequent release if applicable). PREPARING AUTHORIZED MODIFICATION LABEL 1. Obtain and prepare the Authorized Modification Label. Write the modification completed, your P&A; code, the date of repair, the program type and program number as shown below. See Figure 1. 2. Apply the label to a clear area of the upper radiator support. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5320 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5321 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns PROM - Programmable Read Only Memory: Customer Interest Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5327 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5328 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5329 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5330 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped PROM - Programmable Read Only Memory: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5335 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5336 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5337 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5338 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5339 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5340 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns PROM - Programmable Read Only Memory: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5346 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5347 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5348 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5349 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5354 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5355 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped PROM - Programmable Read Only Memory: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5360 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5361 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5362 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5363 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5364 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5365 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming Technical Service Bulletin # 00B58 Date: 001201 Information 00B58 OWNER NOTIFICATION PROGRAM Certain 2001 Model Year Explorer Sport Trac 4x2 Vehicles - Powertrain Calibration Update Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5370 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5371 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT Promptly correct all affected vehicles on the enclosed list and other eligible vehicles which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Refunds do not apply to the program. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5372 LABOR ALLOWANCES Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR SPORT TRAC VEHICLES SERVICE PROCEDURE 1. Reprogram the Powertrain Control Module (PCM) with the latest calibration using one of the following two (2) methods: ^ Worldwide Diagnostic System (WDS). Use WDS CD-ROM B10 release (or subsequent release if applicable) available via Fordstar, or for Non-Fordstar dealers available at: http://www.fordtechservice.com/vdirs/wds ^ Service Bay Technical System (SBTS) and the New Generation Star (NGS) Tester with Rotunda Flash Cable (007-00531) and Rotunda Flash Card (007-00532). Use the October release CD-ROM (or subsequent release if applicable). PREPARING AUTHORIZED MODIFICATION LABEL 1. Obtain and prepare the Authorized Modification Label. Write the modification completed, your P&A; code, the date of repair, the program type and program number as shown below. See Figure 1. 2. Apply the label to a clear area of the upper radiator support. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5373 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5374 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns PROM - Programmable Read Only Memory: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5380 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5381 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5382 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 5383 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5388 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5389 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped PROM - Programmable Read Only Memory: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5394 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5395 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5396 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5397 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5398 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 5399 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5405 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5406 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming Technical Service Bulletin # 00B58 Date: 001201 Information 00B58 OWNER NOTIFICATION PROGRAM Certain 2001 Model Year Explorer Sport Trac 4x2 Vehicles - Powertrain Calibration Update Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5411 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5412 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT Promptly correct all affected vehicles on the enclosed list and other eligible vehicles which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Refunds do not apply to the program. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5413 LABOR ALLOWANCES Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR SPORT TRAC VEHICLES SERVICE PROCEDURE 1. Reprogram the Powertrain Control Module (PCM) with the latest calibration using one of the following two (2) methods: ^ Worldwide Diagnostic System (WDS). Use WDS CD-ROM B10 release (or subsequent release if applicable) available via Fordstar, or for Non-Fordstar dealers available at: http://www.fordtechservice.com/vdirs/wds ^ Service Bay Technical System (SBTS) and the New Generation Star (NGS) Tester with Rotunda Flash Cable (007-00531) and Rotunda Flash Card (007-00532). Use the October release CD-ROM (or subsequent release if applicable). PREPARING AUTHORIZED MODIFICATION LABEL 1. Obtain and prepare the Authorized Modification Label. Write the modification completed, your P&A; code, the date of repair, the program type and program number as shown below. See Figure 1. 2. Apply the label to a clear area of the upper radiator support. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5414 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 00B58 > Dec > 00 > Campaign - Powertrain Control Module Reprogramming > Page 5415 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5422 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5423 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5424 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5447 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift strategy. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected, or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5448 Pressure Regulating Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5449 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5450 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5451 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5455 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1. Remove the screws and position the hood release handle out of the way. 2. Remove the two screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5456 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid Clamp Screws 53 - 71 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5460 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5461 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5462 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5463 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5486 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5487 Shift Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5488 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5489 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5490 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5494 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5495 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5496 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5519 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5520 Torque Converter Clutch Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5521 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5522 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5523 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5529 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5530 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5531 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5554 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift strategy. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected, or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5555 Pressure Regulating Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5556 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5557 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5558 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5562 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1. Remove the screws and position the hood release handle out of the way. 2. Remove the two screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5563 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid Clamp Screws 53 - 71 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5567 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5568 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5569 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5570 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5593 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5594 Shift Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5595 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5596 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5597 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5601 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5602 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5603 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5626 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5627 Torque Converter Clutch Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5628 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5629 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5630 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover Band Apply Servo: Customer Interest A/T - 5R44E/5R55E Fluid Leak at Servo Cover Article No. 02-8-3 04/29/02 TRANSMISSION - 5R44E OR 5R55E - FLUID LEAK AT SERVO COVER - VEHICLES PRODUCED 6/1/2001 THROUGH 3/31/2002 EQUIPPED WITH 2.3L, 3.0L OR 4.0L ENGINES FORD: 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some vehicles equipped with a 2.3L, 3.0L or 4.0L engine and 5R44E or 5R55E automatic transmission, produced 6/1/2001 through 3/31/02, operating in cold climates, may exhibit a fluid leak at the transmission Servo Cover(s). This, may be caused by the Servo Cover. ACTION Verify the condition. If the condition exists, the Servo Cover(s) may need to be replaced with new cover(s) (Figure 1). Check the transmission fluid level and fluid condition. If fluid is just low and the fluid condition is not burnt, refer to the following Service Procedure to replace the Servo Cover(s). If the transmission shows evidence of damage due to no fluid, no engagements or severely burnt fluid, the transmission may need additional repair or replacement. Follow normal repair or replacement procedures when servicing anything other than the Servo Cover(s). SERVICE PROCEDURE Service Procedure for replacing the Front or Intermediate Servo Cover: NOTE AN IN-LINE FLUID FILTER OR AN IN-LINE FLUID FILTER KIT IS NOT REQUIRED FOR THIS PROCEDURE. 1. Remove the catalytic converter. 2. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve Body", Section 307-01, remove the Main Control assembly. NOTE DO NOT ALLOW THE BAND ADJUSTMENT SCREW TO BACK OUT COMPLETELY OR THE BAND STRUT WILL FALL OUT OF POSITION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5639 3. Remove and discard the band lock nut, then back out the adjusting screw three to four turns. 4. Install special service tool 307-340 (T95L-77028-A). 5. Tighten special tool to compress the servo spring. CAUTION THE SERVO COVER IS UNDER SPRING TENSION. 6. Remove the Servo Cover retaining ring. 7. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. NOTE DO NOT ALLOW THE PISTON TO COME OUT OF THE BORE. 8. Tap lightly on the cover, then remove the cover. NOTE DO NOT DAMAGE THE COVER SEALS DURING INSTALLATION. DO NOT PRESS SERVO COVER AND SEALS PAST THE RELIEF HOLE IN THE CASE OR SEALS MAY BE DAMAGED. 9. Lubricate Servo Cover Seal and install a new Servo Cover Assembly onto the piston and into the piston bore Refer to the Servo Cover Application Chart for Servo Cover applications. 10. Install special service tool 307-340 (T95L-77028-A). 11. Tighten special tool to compress the Servo Cover and spring. 12. Install retaining ring. 13. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. Clean residual fluid from Servo Cover area. NOTE INSTALL, BUT DO NOT TIGHTEN, A NEW LOCK NUT ON THE SCREW. NOTE THE WRENCH WILL CLICK AT THE SPECIFIED TORQUE. NOTE IF REPLACING BOTH SERVO COVERS, ORDER TWO (2) NEW LOCK NUTS. 14. Apply petroleum jelly to the lock nut seal. Install new locknut, but do not tighten at this time. Using special service tool 307-S022, tighten the band adjusting screw to 14 N.m (10 Lb-ft), then back oft the adjusting screw exactly two (2) turns and hold that position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5640 15. Hold the band adjusting screw stationary and tighten the band locknut to 47-61 N.m (35-44 lb-ft). 16. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve Body", Section 307-01, Install the Main Control assembly. 17. Reinstall the catalytic converter. Parts Block OTHER APPLICABLE ARTICLES: 02-8-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7L173 01 OASIS CODES: 504000, 510000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 5R44E/5R55E Fluid Leak at Servo Cover Article No. 02-8-3 04/29/02 TRANSMISSION - 5R44E OR 5R55E - FLUID LEAK AT SERVO COVER - VEHICLES PRODUCED 6/1/2001 THROUGH 3/31/2002 EQUIPPED WITH 2.3L, 3.0L OR 4.0L ENGINES FORD: 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some vehicles equipped with a 2.3L, 3.0L or 4.0L engine and 5R44E or 5R55E automatic transmission, produced 6/1/2001 through 3/31/02, operating in cold climates, may exhibit a fluid leak at the transmission Servo Cover(s). This, may be caused by the Servo Cover. ACTION Verify the condition. If the condition exists, the Servo Cover(s) may need to be replaced with new cover(s) (Figure 1). Check the transmission fluid level and fluid condition. If fluid is just low and the fluid condition is not burnt, refer to the following Service Procedure to replace the Servo Cover(s). If the transmission shows evidence of damage due to no fluid, no engagements or severely burnt fluid, the transmission may need additional repair or replacement. Follow normal repair or replacement procedures when servicing anything other than the Servo Cover(s). SERVICE PROCEDURE Service Procedure for replacing the Front or Intermediate Servo Cover: NOTE AN IN-LINE FLUID FILTER OR AN IN-LINE FLUID FILTER KIT IS NOT REQUIRED FOR THIS PROCEDURE. 1. Remove the catalytic converter. 2. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve Body", Section 307-01, remove the Main Control assembly. NOTE DO NOT ALLOW THE BAND ADJUSTMENT SCREW TO BACK OUT COMPLETELY OR THE BAND STRUT WILL FALL OUT OF POSITION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5646 3. Remove and discard the band lock nut, then back out the adjusting screw three to four turns. 4. Install special service tool 307-340 (T95L-77028-A). 5. Tighten special tool to compress the servo spring. CAUTION THE SERVO COVER IS UNDER SPRING TENSION. 6. Remove the Servo Cover retaining ring. 7. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. NOTE DO NOT ALLOW THE PISTON TO COME OUT OF THE BORE. 8. Tap lightly on the cover, then remove the cover. NOTE DO NOT DAMAGE THE COVER SEALS DURING INSTALLATION. DO NOT PRESS SERVO COVER AND SEALS PAST THE RELIEF HOLE IN THE CASE OR SEALS MAY BE DAMAGED. 9. Lubricate Servo Cover Seal and install a new Servo Cover Assembly onto the piston and into the piston bore Refer to the Servo Cover Application Chart for Servo Cover applications. 10. Install special service tool 307-340 (T95L-77028-A). 11. Tighten special tool to compress the Servo Cover and spring. 12. Install retaining ring. 13. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. Clean residual fluid from Servo Cover area. NOTE INSTALL, BUT DO NOT TIGHTEN, A NEW LOCK NUT ON THE SCREW. NOTE THE WRENCH WILL CLICK AT THE SPECIFIED TORQUE. NOTE IF REPLACING BOTH SERVO COVERS, ORDER TWO (2) NEW LOCK NUTS. 14. Apply petroleum jelly to the lock nut seal. Install new locknut, but do not tighten at this time. Using special service tool 307-S022, tighten the band adjusting screw to 14 N.m (10 Lb-ft), then back oft the adjusting screw exactly two (2) turns and hold that position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5647 15. Hold the band adjusting screw stationary and tighten the band locknut to 47-61 N.m (35-44 lb-ft). 16. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve Body", Section 307-01, Install the Main Control assembly. 17. Reinstall the catalytic converter. Parts Block OTHER APPLICABLE ARTICLES: 02-8-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7L173 01 OASIS CODES: 504000, 510000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 5648 Band Apply Servo: Specifications Transmission Servo Heat Shield Nut 71 - 97 in.lb Transmission Servo Heat Shield Stud 106 - 142 in.lb Front Band Locknut 35 - 45 ft.lb Low/Reverse Servo Cover Screws 106 - 124 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment Band Apply Servo: Adjustments Front Band Adjustment Front Band Adjustment Special Tools Special Tool(s) 1. Raise the vehicle on a hoist. 2. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 3. CAUTION: ^ Do not allow front band adjustment screw to back out. Band strut can fall out of position; ^ Throw the locknut away. The locknut is not reusable for assembly. Remove and discard the locknut. 4. CAUTION: ^ Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal. ^ The servo must be installed prior to band adjustment. NOTE: The wrench will click at the specified torque. Install new locknut, do not tighten at this time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5651 Using the special tool, tighten front band adjustment screw then, back off the front band adjustment screw exactly two (2) turns and hold that position. 5. Tighten the front band locknut. 1. Hold the front band adjustment screw stationary. 2. Tighten the front band locknut. 6. Install the shift cable. 1. Install the shift cable. 2. Install the shift cable to the manual control lever. 7. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5652 Band Apply Servo: Adjustments Intermediate Band Adjustment Intermediate Band Adjustment 1. Raise and support the vehicle. 2. Remove the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the bracket. 3. Remove the digital Transmission Range (TR) sensor. 4. CAUTION: ^ Do not allow the screw to back out. Band strut can fall out of position. ^ Throw the locknut away. The locknut is not reusable for assembly. Remove and discard the locknut. 5. CAUTION: ^ Install, but do not tighten, a new locknut on the screw. Apply petroleum jelly to the locknut seal. ^ The intermediate servo must be installed prior to band adjustment. NOTE: The wrench will click at the specified torque. Install new locknut, do not tighten at this time. Using the special tool, tighten the screw then, back off the screw exactly two (2) turns and hold that position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5653 6. Tighten the intermediate band locknut. 1. Hold the screw stationary. 2. Tighten the intermediate band locknut. 7. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 8. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 9. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5654 10. Connect the digital Transmission Range (TR) sensor electrical connector. 11. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 12. Verify that the shift cable is adjusted. 13. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo Band Apply Servo: Service and Repair Front Servo Front Servo Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support vehicle. 3. Remove the shift cable. 1. Disconnect the shift cable from the manual control ]ever. 2. Remove the shift cable from the bracket. 4. Remove the digital Transmission Range (TR) sensor. 5. Remove the main control valve body. 6. Remove the Three Way Catalytic Converter (TWC). 7. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5657 Loosen the nut and position the heat shield out of the way. 8. Remove the front band locknut and unscrew the front band adjusting screw. ^ Discard the front band locknut after removal. 9. CAUTION: The servo cover is under spring pressure. Using the special tool, remove the front band servo cover retaining ring. ^ Slowly remove tension on the J-hook nut and remove the servo cover compressor. 10. CAUTION: The special tool should be used to prevent damage to servo and bore. Using the special tool, remove the front band servo cover, servo piston and servo piston spring. ^ Insert the special tool into the transmission case, locate on servo rod, and remove the front band servo cover, servo piston and servo piston spring. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5658 1. Assemble the front band servo cover, front band servo piston and the servo piston spring. 1. Install the front band servo piston into the front band servo cover. 2. Install the servo piston spring on the front band servo piston. 2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past relief hole in case, or O-ring damage may occur. Install the front band servo assembly into the transmission case. ^ Lubricate the front band servo cover O-ring with petroleum jelly. 3. Using the special tool, install the front band servo cover retaining ring. 4. Install the main control valve body. 5. Adjust the front band. 6. If equipped, position the transmission servo heat shield on the transmission and install the nut. 7. Install the three way catalytic converter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5659 8. Install the shift cable. 1. Install the shift cable. 2. Install the shift cable to the manual control lever. 9. Install the digital Transmission Range (TR) sensor. 10. Lower the vehicle. 11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 12. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5660 Band Apply Servo: Service and Repair Intermediate Servo Intermediate Servo Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different up shifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the bracket. 4. Remove the digital Transmission Range (TR) sensor. 5. Remove the Three Way Catalytic Converter (TWC). 6. Remove the main control valve body. 7. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5661 Loosen the nut and position the heat shield out of the way. 8. Remove the intermediate band locknut and unscrew the screw. ^ Discard the intermediate band locknut after removal. 9. CAUTION: The servo cover is under spring tension. Use caution when removing. Using the special tool, remove the intermediate band servo cover retaining ring. ^ Slowly remove tension on the J-hook nut and remove the servo cover compressor. 10. CAUTION: The special tool should be used to prevent damage to the servo, servo cover and bore. Using the special tool, remove the intermediate band servo cover, intermediate band servo piston and servo piston spring. ^ Insert the special tool into the transmission case, and remove the servo cover, intermediate band servo piston and servo piston spring. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5662 1. Assemble the intermediate band servo cover, intermediate band servo piston and the servo piston spring. 1. Install the intermediate band servo piston into the intermediate band servo cover. 2. Install the servo piston spring on the intermediate band servo piston. 2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past relief hole in case, or O-ring damage may occur. Install the intermediate band servo piston assembly into the transmission case. ^ Lubricate intermediate band servo cover O-ring with petroleum jelly. 3. Using the special tool, install the intermediate band servo cover retaining ring. 4. Adjust the intermediate band. 5. Install the main control valve body. 6. Install the digital Transmission Range (TR) sensor. 7. If equipped, position the transmission servo heat shield on the transmission and install the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5663 8. Install the shift cable. 1. Install the shift cable. 2. Install the shift cable to the manual control lever. 9. Install the three way catalytic converter. 10. Lower the vehicle. 11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 12. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5664 Band Apply Servo: Service and Repair Low/Reverse Servo Assembly Low/Reverse Servo Assembly Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the transmission pan. 4. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 5. Remove the low/reverse band servo cover. 1. Remove the low/reverse band servo cover screws. 2. Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket. 6. Remove the low/reverse band servo piston and rod assembly. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5665 1. Clean and inspect the low/reverse band servo piston bore and the low/reverse band servo piston and rod. 2. Install the low/reverse band servo piston and rod. 1. Install the low/reverse band servo piston and rod assembly. 2. Install a new low/reverse band servo separator plate cover gasket. 3. Install the low/reverse band servo cover. ^ Loosely install the low/reverse band servo piston cover screws. 3. Tighten the servo cover screws in the sequence shown. 4. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. 5. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5666 ^ Loosely install the transmission fluid pan screws. 6. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 9. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Extension Housing screws 27-39 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5670 Extension Housing: Service and Repair Extension Housing Gasket Removal 1. Raise and support the vehicle. 2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 3. Remove the rear driveshaft. 1. Remove the bolts. 2. Remove the rear driveshaft. 4. Remove the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5671 5. Raise and support the transmission. 6. Remove the transmission mount. 1. Remove the screws. 2. Remove the transmission mount. 7. Remove the extension housing screws and studs. 8. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing. Remove the extension housing. Discard the extension housing gasket. Installation 1. Clean the extension housing and install new extension housing gasket. Make sure that the parking pawl, spring and shaft are correctly installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5672 2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. 1. Position the extension housing. 2. Install the extension housing screws. 3. Install the extension housing studs. 3. Install the transmission mount. 1. Position the transmission mount on the extension housing. 2. Install the transmission mount-to-extension housing screws. 4. Install the transmission mount into the crossmember and tighten the transmission mount nuts. 5. NOTE: Align the driveshaft with the marks made during removal to ensure correct balance. Align and install the rear driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5673 6. Install the bolts. 7. Lower the vehicle. 8. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ..................................................................... 10.0 qts Note: Approximately Dry Fill Capacity Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5678 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................................. MERCON V Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change Fluid - A/T: Service and Repair A/T Fluid Level Check and Condition, Change Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5681 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5682 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5683 ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5684 Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. 1. With the vehicle in PARK, position on a hoist. 2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail and positioned aside for fluid pan removal. If equipped, loosen the nut and position the heat shield aside. 3. Place a drain pan under the transmission fluid pan. 4. Drain the transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to drain. After the fluid is drained, remove the front two transmission fluid pan screws. 5. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5685 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. Refill 1. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan ^ Loosely install the transmission fluid pan screws. 2. Tighten the transmission fluid pan screws. ^ Tighten the transmission fluid pan screws in a crisscross sequence. 3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the vehicle. 5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5686 cross-hatched area of the fluid level indicator). 6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the gears. 8. Check the transmission fluid level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition, Change > Page 5687 Fluid - A/T: Service and Repair Automated Equipment Transmission Fluid Drain and Refill-Automated Equipment Special Tool(s) Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. CAUTION: Always refer to the instructions supplied with the flush and fill machine. NOTE: This is a new procedure for draining and adding transmission fluid using a suitable transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will help remove any foreign material trapped in the fluid coolers. 4. Carry out the fluid exchange process. Refill 1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Transmission Fluid Filter Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 5691 Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Removal 1. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 5692 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 5693 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 5694 ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Transmission Cooler Lines To Case Connectors 26 - 32 ft.lb Transmission Cooler Line Nut 18 - 23 ft.lb Transmission Fluid Cooler Tube Fitting To Radiato 10 - 16 ft.lb Transmission Fluid Cooler Tube To Case Fitting 18 - 23 ft.lb Transmission Cooler Lines Bracket Bolts 28 - 38 in.lb Transmission Auxiliary Fluid Cooler Hose Clamps 27 - 35 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5698 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes Removal 1. Raise and support the vehicle. 2. Remove the radiator air deflector. 1. Remove the bolts. 2. Remove the radiator air deflector. 3. Remove the nut, bolt and transmission cooler line bracket. 4. Remove the transmission fluid cooler tubes. 1. Remove the clips. 2. Disconnect the fittings. ^ Use a backup wrench to hold the case fitting secure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5699 3. Remove the nut. 4. Remove the transmission fluid cooler tubes. Installation 1. NOTE: When a transmission fluid cooler tube is replaced, each replacement tube must be fabricated from the same size tube as the original. Shape a new transmission fluid cooler tube. ^ Use the prior tube as a guide. ^ Install the appropriate fittings. 2. CAUTION: ^ To prevent damage, make sure all plugs are removed from port openings before installing tubes. ^ To prevent cross threading, all tube nuts must be hand started before being torqued to specification. Install the transmission fluid cooler tubes. 1. Install the clips. 2. Connect the tube fittings to the radiator. 3. Connect the tube fittings to the transmission. ^ Use a backup wrench to hold the case fitting secure. 4. Install the tube bracket nut. 5. Install the transmission fluid cooler tubes. 3. Install the nut, bolt, and transmission cooler line bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5700 4. Install the radiator air deflector. ^ Install the bolts. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill transmission fluid to the proper level using the correct fluid and inspect for leaks. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility Fluid Pan: Technical Service Bulletins A/T - 5R44E/5R55E Part Level Change/Compatibility TSB 06-24-13 11/20/06 5R44E / 5R55E SERVICE PART LEVEL CHANGE / COMPATIBILITY FORD: 1997 Aerostar 1997-2001 Explorer 1997-2007 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac MERCURY: 1998-2001 Mountaineer ISSUE Some vehicles equipped with a 5R44E or 5R55E automatic transmission may require repair of the transmission. This TSB is being published as informational only in order to avoid mix I match of incorrect service parts which will cause a fluid leak. Beginning with 8/29/2006 production, the 5R44E or 5R55E automatic transmission will have a new transmission case, fluid pan, a REUSABLE fluid pan gasket and new fluid pan screws. ACTION Follow the Service Tips. SERVICE TIPS NOTE DO NOT MIX AND MATCH PARTS OR LEAKAGE WILL OCCUR. NOTE THE NEW PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The 5R44E / 5R55E transmission pan gasket has been redesigned to be reusable if it is removed for a non-leak related transmission service concern. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. The case and fluid pan rails have been redesigned to properly mate with the new gasket to eliminate fluid leaks. The new case, pan, and gasket maybe used to service past model transmissions from 1997. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5705 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5706 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5707 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5708 For 1997-2007 (early production) 4R44E I 5R44E and 5R55E when servicing the fluid pan gasket (7A191), the fluid pan (7A194) or the case (7005) do not mix and match old level and new level parts. The old level gasket, refer to Figure 3 (7A191) will be continued for past model applications. If replacing the older design level case, refer to Figure 1 (7005) and/or old lever fluid pan, refer to Figure 2 (7A194), ALL new components must be used. This includes the case (7005), refer to Figure 4, fluid pan (7A194), refer to Figure 5, fluid pan gasket (7A191), refer to Figure 6 and pan screws (W500212) (new torque specification - 7 lb-ft (10 N.m) refer to Figure 7. For correct part numbers refer to your parts catalogue. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5709 Fluid Pan: Specifications Transmission Fluid Pan Screws 115 - 132 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5710 Fluid Pan: Service and Repair "For information regarding this component please refer to Transmission Filter Service And Repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Fluid Pump Screws 16 - 21 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair Parking Pawl: Service and Repair Park System Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 5. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5721 6. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. 7. Disconnect the solenoid electrical connectors. 1. Disconnect shift solenoids SSB and SSD electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 8. CAUTION: The TCC solenoid and converter modulator valve may pop out of their bore. This may damage the solenoid or converter modulator valve. Remove the EPC, SSB, and SSD solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the EPC, SSB, and SSD solenoids. 9. CAUTION: Do not pry on the other wires or damage to the connector case surface may result. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5722 Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector from the transmission case (16 pin) electrical connector. 1. Disconnect the TSS sensor electrical connector. 2. Remove the TSS sensor wire locator. 10. CAUTION: Do not overstretch the retaining spring. Remove the transmission case (16 pin) electrical connector retaining spring. 11. CAUTION: Do not damage the connector or harness. Remove the transmission case (16 pin) electrical connector. ^ Compress the tabs on the connector. ^ Push the connector out of the transmission case. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5723 12. Remove the manual control valve detent lever spring. 1. Remove the screw. 2. Remove the spring. 13. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin. Remove the manual valve inner lever nut. 14. Remove the manual valve inner lever and parking lever actuating rod. 15. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they can be installed in their original alignment. Mark the rear driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5724 16. Remove the rear driveshaft. 1. Remove the bolts. 2. Remove the rear driveshaft. 17. If equipped, remove the transfer case. 18. NOTE: ^ If damage is found to the parking gear, the transmission must be removed and disassembled. ^ The parking pawl, parking pawl return spring and parking pawl shaft may fall out during removal of the extension housing. Remove the extension housing and discard the extension housing gasket. 19. Inspect the parking pawl, parking pawl return spring and the parking pawl shaft. ^ Install new components if required. Installation 1. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Verify that the output shaft is locked in the, PARK position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5725 Align the flats of the manual valve inner lever with the flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft. 2. CAUTION: Do not bend the manual valve inner lever pin. Install the manual valve inner lever nut. 3. Install the manual valve detent spring. 4. Clean the extension housing and install a new extension housing gasket. Make sure that the parking pawl, spring, and shaft is correctly installed. 5. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5726 Install the extension housing. 1. Position the extension housing. 2. Install the extension housing screws. 3. Install the extension housing stud. 6. If equipped, install the transfer case. 7. NOTE: Align the drive shaft with the marks made during removal to ensure correct balance. Install the rear driveshaft bolts. 8. NOTE: ^ Make sure the tab is in the lock position. ^ Install new O-rings on the transmission case (16 pin) electrical connector. Install the transmission case (16 pin) electrical connector. ^ Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly. 9. Press the transmission case (16 pin) electrical connector through the case until a click is heard. 10. CAUTION: Align the slot on the TSS Sensor electrical connector with the slot in the 16 pin case connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5727 Install the TSS sensor wire. 1. Install the TSS sensor wire into (16 pin) electrical connector. 2. Install the TSS sensor wire into locator. 11. CAUTION: Do not overstretch the retaining spring. Install the transmission case (16 pin) electrical connector retaining spring. 12. Install the EPC, SSD, and SSB solenoids. 13. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5728 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 14. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors. 15. CAUTION: Excessive pressure may break the retaining pins. Install the wire loom guide and protector. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the wire loom guide and protector. 16. Install the transmission fluid pan. 1. Install a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5729 17. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 18. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 19. Lower the vehicle. 20. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur While the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 21. Fill transmission to correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise Planetary Gears: Customer Interest A/T - 5R55E 1st/2nd Gear Whining Noise Article No. 02-22-2 11/11/02 ^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 5R55E TRANSMISSION AND 4.0L ENGINE ONLY ^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002, equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary assemblies and/or the driveshaft. ACTION Verify that only these conditions exist and no DTCs are present. If other conditions are present and DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using the chart provided, select the parts that need to be replaced. NOTE IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED. SERVICE PROCEDURE Gear Whine Service Procedure 1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need to be replaced, refer to Application and Component replacement chart shown. 2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate Workshop Manual section for driveshaft removal/replacement. 3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual, Section 307-01, Transmission Removal procedures, remove the transmission. 4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement chart. NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5738 NOTE BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE. 5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly (7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond the Reverse Planetary assembly. 6. Using the appropriate Transmission Assembly procedures, assemble the transmission and install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service Forward Planetary Assembly (XL2Z-7A398-AA). 7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission Installation procedures, install transmission. 8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the appropriate application listed. 9. Verify repair. Clear DTCs. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022202A Replace Transmission 5.5 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2 022202B Replace Transmission 7.0 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4 022202C Replace Driveshaft 0.4 Hr. Only 2002-2003 Explorer Sport Trac 4x2 DEALER CODING CONDITION BASIC PART NO. CODE 7A398 42 OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5739 DISCLAIMER Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise Planetary Gears: All Technical Service Bulletins A/T - 5R55E 1st/2nd Gear Whining Noise Article No. 02-22-2 11/11/02 ^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 5R55E TRANSMISSION AND 4.0L ENGINE ONLY ^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002, equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary assemblies and/or the driveshaft. ACTION Verify that only these conditions exist and no DTCs are present. If other conditions are present and DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using the chart provided, select the parts that need to be replaced. NOTE IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED. SERVICE PROCEDURE Gear Whine Service Procedure 1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need to be replaced, refer to Application and Component replacement chart shown. 2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate Workshop Manual section for driveshaft removal/replacement. 3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual, Section 307-01, Transmission Removal procedures, remove the transmission. 4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement chart. NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5745 NOTE BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE. 5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly (7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond the Reverse Planetary assembly. 6. Using the appropriate Transmission Assembly procedures, assemble the transmission and install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service Forward Planetary Assembly (XL2Z-7A398-AA). 7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission Installation procedures, install transmission. 8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the appropriate application listed. 9. Verify repair. Clear DTCs. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022202A Replace Transmission 5.5 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2 022202B Replace Transmission 7.0 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4 022202C Replace Driveshaft 0.4 Hr. Only 2002-2003 Explorer Sport Trac 4x2 DEALER CODING CONDITION BASIC PART NO. CODE 7A398 42 OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5746 DISCLAIMER Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5750 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5751 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5752 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5775 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift strategy. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected, or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5776 Pressure Regulating Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5777 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5778 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5779 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T Seals and Gaskets: Service and Repair Extension Housing Seal, A/T Extension Housing Oil Seal Special Tools Special Tool(s) Removal 1. Raise and support the vehicle. 2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 3. Remove the rear driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5784 1. Remove the rear driveshaft bolts. 2. Remove the rear driveshaft. 4. Using the special tools, remove the extension housing seal. 5. CAUTION: Use the extension housing bushing remover carefully so that the seal area is not damaged. Using the special tool, remove the extension housing bushing. Installation 1. CAUTION: The lube hole in the extension housing bushing must be aligned with the lube groove in the extension housing. This groove is located at the 3 o'clock position when viewed from the rear. NOTE: Inspect the counterbore of the extension housing for burrs. Remove any burrs from the extension housing counterbore with an oil stone. Position the extension housing bushing into the extension housing. 2. CAUTION: The tool will bottom when bushing is in the correct position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5785 Using the special tool, install the extension housing bushing. 3. Position new extension housing seal with drain hole in the 6 o'clock position. 4. Using the special tool, install the extension housing seal. 5. NOTE: Inspect the driveshaft slip-yoke for wear and damage. Install a new component if required. Align the driveshaft with the marks made during removal to ensure correct balance. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5786 6. Install the rear driveshaft bolts. 7. Lower the vehicle. 8. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-OM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5787 Seals and Gaskets: Service and Repair Shift Shaft Seal Manual Control Lever Shaft and Seal Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. , Disconnect the battery ground cable. 2. Raise and support vehicle. 3. NOTE: If equipped, transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. NOTE: It is not necessary to remove the transmission fluid filter to carry out this procedure. Remove the transmission fluid pan. 5. Remove the digital Transmission Range (TR) sensor. 6. Remove the manual control valve detent lever spring. 1. Remove the manual control valve detent lever spring screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5788 2. Remove the manual control valve detent lever spring. 7. CAUTION: Do not damage the valve inner lever pin. Remove the manual valve inner lever nut. 8. Separate the manual valve inner lever and the parking lever actuating rod. 9. CAUTION: Do not damage the case fluid pan rail. Remove the manual control lever shaft spring pin. ^ Tap lightly on each side of the manual control lever shaft spring pin with a drift punch. ^ Pry the spring pin out of its bore. 10. Remove the manual control lever shaft. 11. CAUTION: Do not damage the bore. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5789 Remove the manual control lever shaft seal. Installation 1. Using the special tool, install the manual control lever shaft seal. ^ Lubricate the manual control lever shaft seal with petroleum jelly. 2. Install the manual control lever shaft. 3. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin. Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. ^ Tap the manual control lever shaft spring pin into the transmission case. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5790 4. Align flats of the manual valve inner lever with flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft. 5. CAUTION: Do not bend the manual valve inner lever pin. Install the manual valve inner lever nut. 6. CAUTION: Park pawl actuating rod must be correctly installed into parking pawl and guide cup located in extension housing. Verify park linkage function. Verify that the output shaft is locked in the PARK position. 7. Install the manual valve detent spring. 8. Install the transmission fluid pan with new pan gasket. 9. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 10. Install the digital Transmission Range (TR) sensor. 11. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5791 12. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 13. Fill the transmission to correct level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5796 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5797 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1. Remove the cover. 2. Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5801 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5802 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5803 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5804 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5805 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5811 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5812 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 Transmission Speed Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Transmission Speed Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5836 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5837 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5838 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5864 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5869 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1. Remove the screws and position the hood release handle out of the way. 2. Remove the two screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5870 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid Clamp Screws 53 - 71 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5874 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5875 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5876 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5877 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5900 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5901 Shift Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5902 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5903 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5904 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments Shifter A/T: Adjustments Selector Lever Indicator Adjustment 1. Remove the lower steering column opening finish panel. 1. Remove the screws and position the hood release handle out of the way. 2. Remove the two screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 2. Remove the five bolts and the lower steering column opening finish panel reinforcement. 3. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise two detents (OD position). 4. Hang a 1.4 kg (3 lbs.) weight on the gearshift lever. 5. Rotate the thumb wheel to center the selector lever indicator in the middle of the OD position. 6. Remove the 1.4 kg (3 lbs.) weight. 7. Rotate the gearshift lever into each detent to verify that the selector lever indicator matches the selected range. Readjust, if necessary. 8. Install the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments > Page 5908 9. Install the lower steering column opening finish panel and the hood release handle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments > Page 5909 Shifter A/T: Service and Repair Selector Lever Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1. Remove the screws and position the hood release handle out of the way. 2. Remove the two screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments > Page 5910 5. Remove the ignition switch lock cylinder. 1. Rotate the ignition switch lock cylinder to the RUN position. 2. Press the lock cylinder release pin and remove the ignition switch lock cylinder. 6. Remove the lower steering column shroud. 1. If so equipped, remove the tilt wheel handle and shank. 2. Remove the three screws. 3. Remove the lower steering column shroud. 7. Remove the upper steering column shroud. 8. Disconnect the Transmission Control Switch (TCS) harness connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments > Page 5911 9. Separate the TCS harness from the locators and the gearshift lever cover from the steering column. 10. CAUTION: Never reinstall the old gearshift lever pin. Remove the gearshift lever pin and the gearshift lever. Discard the gearshift lever pin. 11. To install, reverse the removal procedure. 12. Prove out the air bag system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Bolts Retaining The Shift Cable Bracket To The Transmission 30 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5916 Shift Cable: Adjustments Selector Lever Cable Adjustment 1. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise two detents (OD position). 2. Hang a 1.4 kg (3 lbs.) weight on the gearshift lever. 3. Raise and support the vehicle. 4. CAUTION: Adjust the shift cable only in the OD position. Adjust the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Insert a flat blade screwdriver between the end of the shift cable adjustment lock tab and the housing and twist the screwdriver to disengage the lock tab snaps. Pull the shift cable adjustment lock tab outward to the unlock position. 3. Place the manual control lever in the OD position. ^ Rotate the manual control lever forward until travel stops. Then, move the manual control lever back two detents to the OD position. 4. Connect the shift cable to the manual control lever. 5. Push the shift cable adjustment lock tab inward to the lock position. 5. Lower the vehicle. 6. Remove the 1.4 kg (3 lbs.) weight. 7. Verify that the engine will start in P and N and that the reversing lamps illuminate in R. If not, repeat the adjustment procedure. 8. Check that the Digital Transmission Range (DTR) sensor adjustment is correct. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5917 Shift Cable: Service and Repair Selector Lever Cable and Bracket Removal 1. Raise and support the vehicle. 2. Disconnect the shift cable from the transmission. 1. Disconnect the shift cable from the manual control lever. 2. Depress the lock tabs and disconnect the shift cable from the shift cable bracket. 3. Remove the bolts and the shift cable bracket from the transmission. 4. Lower the vehicle. 5. Disconnect the shift cable from the steering column. 1. Disconnect the shift cable from the transmission selector lever arm and support. 2. Disconnect the shift cable from the steering column bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5918 6. Push the rubber grommet through the bulkhead. 7. Locate the shift cable retainer tabs, protruding through the floor pan, underneath the carpet and insulation. While squeezing the tabs together, push the tabs out of the floor pan. 8. From the engine compartment, remove the shift cable from the vehicle. Installation 1. From inside the vehicle, feed the shift cable through the opening in the bulkhead and downward toward the transmission. Do not seat the rubber grommet in the bulkhead opening at this time. 2. Connect the shift cable to the steering column. 1. Connect the shift cable to the steering column bracket. 2. Connect the shift cable to the transmission selector lever arm and support. 3. From the engine compartment, connect the shift cable retainer to the floor pan. 4. From inside the vehicle, verify that the retainer tabs have seated on the floor pan. Reposition the insulation and the carpet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5919 5. Seat the rubber grommet in the bulkhead opening. 6. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise two detents (OD position). 7. Hang a 1.4 kg (3 lbs.) weight on the gearshift lever. 8. Raise and support the vehicle. 9. Position the shift cable bracket and install the bolts. 10. Connect the shift cable to the shift cable bracket. Do not connect the shift cable to the manual control lever at this time. 11. Adjust the shift cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5923 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5924 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5925 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5948 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5949 Torque Converter Clutch Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5950 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5951 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5952 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 5957 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 5958 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5959 Transmission Cooler: Specifications Transmission Auxiliary Fluid Cooler Bolts 45 - 62 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5960 Transmission Cooler: Description and Operation Transmission Cooling Transmission Cooling Components (Mountaineer Shown, Explorer Similar) All vehicles with automatic transmissions are equipped with integral transmission fluid coolers. The integral transmission fluid cooler is contained inside of the radiator outlet tank and cannot be repaired separately. All (AWD) vehicles are equipped with the transmission auxiliary fluid cooler which is mounted in front of the radiator. In operation, transmission fluid travels from the transmission to the integral transmission fluid cooler to the transmission auxiliary fluid cooler then back to the transmission. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The transmission auxiliary fluid cooler transfers heat from the transmission fluid to the outside air. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview WARNING: Never remove the radiator cap under any conditions while the engine is operating. Failure to follow these instructions could result in personal injury and/or damage to the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first stop. Step back while the pressure is released from the cooling system. When you are certain all the pressure has been released, press down on the radiator cap (with a cloth), turn and remove. Check for fluid leakage. If fluid leakage is found at any of the transmission fluid cooling components, the component must be replaced. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5963 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Page 5964 Transmission Cooler: Service and Repair Auxiliary Transmission Fluid Cooler Removal 1. Disconnect the battery cables. 2. Raise and support the vehicle. 3. Remove the radiator air deflector. 1. Remove the bolts. 2. Remove the radiator air deflector. 4. Place a drain pan under the transmission auxiliary fluid cooler. 5. Loosen the two upper radiator hold down screws. 6. Remove the transmission auxiliary fluid cooler. 1. Disconnect the hoses. 2. Remove the bolts. 3. Remove the transmission auxiliary fluid cooler. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Page 5965 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5972 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5973 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1. Remove the cover. 2. Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Transmission Mount Nuts To Crossmember 64 - 81 ft.lb Transmission Mount-To-Extension Housing screws 64 - 81 ft.lb Crossmember Screws 63 - 87 ft.lb Crossmember Nuts 65 - 85 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5977 Transmission Mount: Service and Repair Transmission Insulator and Retainer Removal NOTE: 4x2 procedure shown. 4x4 similar, front drive shaft will need to be removed. 1. Raise and support the vehicle. 2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 3. Remove the rear driveshaft. 1. Remove the bolts. 2. Remove the rear driveshaft. 4. Remove the transmission mount nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5978 5. Raise and support the transmission. 6. Remove the transmission mount. 1. Remove the screws. 2. Remove the transmission mount. Installation 1. Install the transmission mount. 1. Position the transmission mount on the extension housing. 2. Install the transmission mount-to-extension housing screws. 2. Install the transmission mount into the crossmember and tighten the nuts. 3. NOTE: Align the driveshaft with the marks made during removal to ensure correct balance. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5979 Align and install the rear driveshaft. 4. Install the bolts. 5. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5983 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5984 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5985 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5986 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5987 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5993 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5994 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Transmission Speed Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 Transmission Speed Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6018 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6019 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6020 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6046 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Valve Body: Customer Interest A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Article No. 03-22-10 11/10/03 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 - VEHICLES BUILT BEFORE 12/1/2001 FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002 EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC MERCURY: 1997-2001 MOUNTAINEER This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage. ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: ^ No 2nd Gear ^ No 3rd Gear ^ No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6055 CAUTION A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING. NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. ^ Low Line Pressure While In Drive At WOT ^ No 2nd And/Or No 3rd Gear Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6056 ^ No Engine Braking In Manual 1st ^ DTC P0732, P0733 Or P1762 2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected. 5. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-11-9, 02-13-8 02-08-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032210A Replace Separator Plate 2.8 Hrs. And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve Body And Diagnosis) DEALER CODING CONDITION BASIC PART NO. CODE D100 D8 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Valve Body: All Technical Service Bulletins A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Article No. 03-22-10 11/10/03 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 - VEHICLES BUILT BEFORE 12/1/2001 FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002 EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC MERCURY: 1997-2001 MOUNTAINEER This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage. ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: ^ No 2nd Gear ^ No 3rd Gear ^ No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6062 CAUTION A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING. NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. ^ Low Line Pressure While In Drive At WOT ^ No 2nd And/Or No 3rd Gear Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6063 ^ No Engine Braking In Manual 1st ^ DTC P0732, P0733 Or P1762 2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected. 5. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-11-9, 02-13-8 02-08-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032210A Replace Separator Plate 2.8 Hrs. And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve Body And Diagnosis) DEALER CODING CONDITION BASIC PART NO. CODE D100 D8 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6064 Valve Body: Specifications Main Control Valve Body Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6065 Valve Body: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6066 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6067 Valve Body: Description and Operation For complete Description and Operation of the Valve Body, refer to Transmission and Drivetrain / Automatic Transmission/Transaxle / Description and Operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly Valve Body: Service and Repair Disassembly and Assembly Main Control Valve Body Special Tools Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6070 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6071 Disassembly 1. CAUTION: The SSC solenoid may pop out of its bore. This may damage the solenoid. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6072 Remove the SSA and the SSC clamp and SSA and SSC solenoid. 1. Remove the solenoid clamp screw. 2. Remove the solenoid clamp. 3. Remove the SSA and SSC solenoids. 2. CAUTION: ^ The Torque Converter Clutch solenoid (TCC) solenoid may pop out of its bore. This may damage the solenoid. ^ The converter modulator valve may come out after the TCC solenoid. This may cause damage to the valve. Remove the SSB, SSD, torque converter clutch solenoid, and the EPC solenoid. 1. Remove the solenoid clamp screw. 2. Remove the solenoid clamp. 3. Remove the SSB, SSD, torque converter clutch solenoid and the EPC solenoids. 3. Rotate the main control valve body so that the main control to case gasket is facing up. 4. CAUTION: ^ Valves may come out when rotating the main control valve body. ^ The extension housing lube orifice and relief valves may stick to the separator plate. NOTE: Discard the main control to case gasket. Remove the valve body separator plate screws. 1. Remove the main control to case gasket and discard. 2. Remove the valve body separator plate screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6073 5. Remove valve body separator plate and main control to separating plate gasket. 1. Remove valve body separator plate. 2. Remove main control to separator plate gasket and discard. 6. Remove the extension housing lube orifice and the metal silver Electronic Pressure Control (EPC) limit relief valve and spring. 1. Remove the extension housing lube orifice. 2. Remove the silver metal EPC limit relief valve and spring. 7. Remove the black plastic converter relief valve and spring. 8. Remove the Electronic Pressure Control (EPC) limit circuit screen. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6074 9. Remove the four main control valve body check balls. Assembly 1. CAUTION: Do not lose parts when cleaning or servicing. Thoroughly clean all parts in solvent and blow dry with moisture free compressed air. 2. CAUTION: Do not stone, file or sand the valves. This will remove the anodized finish and may result in further main control or transmission damage. After cleaning the main control valve body, carry out the following: ^ Inspect all valve and plug bores for scoring or burrs. ^ Check all fluid passages for obstructions. ^ Inspect all valves and plugs for burrs. ^ Inspect all mating surfaces for burrs or distortion. ^ Inspect all springs for distortion. ^ Check all valves and plugs for free movement in their respective bores. ^ Valves and plugs, when dry, must fall from their own weight into their respective bores. ^ Roll the manual valve on a flat surface to check for a bent condition. 3. Clean and inspect the EPC solenoid screens. 4. Remove and install new shift solenoid O-rings. 5. Clean and inspect the torque converter clutch solenoid. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6075 6. CAUTION: Make sure that the screen is correctly located. Clean and inspect the Electronic Pressure Control (EPC) limit circuit screen. Install the EPC limit circuit screen. 7. Install the four main control valve body check balls. 8. CAUTION: The springs and valves are not interchangeable. Damage to transmission may occur. Install the dark color plastic converter relief valve and spring. 9. NOTE: The springs and valves are not interchangeable. Install the extension housing lube orifice and the metal silver Electronic Pressure Control (EPC) limit relief valve and spring. 1. Install the extension housing lube orifice. 2. Install the silver metal EPC limit relief valve and spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6076 10. NOTE: ^ Apply petroleum jelly on the valve body separator plate to hold the main control to separator plate gasket in place. ^ Use new separator plate main control to separator plate gasket on installation. Install the main control valve body separator plate and gasket to the main control. 1. Position the main control valve body separator plate to the main control gasket and install separator plate to main control valve body. 2. Install, do not tighten, the three screws. 11. Install the special tools into the main control valve body. 12. Tighten the screws. 13. NOTE: ^ Apply petroleum jelly on the separator plate surface to hold the gasket in place. ^ Use new separator plate gasket on installation. Install new main control to case gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6077 14. Remove the special tools from the main control valve body. 15. Rotate the main control valve body so the valve body separator plate is facing down. 16. CAUTION: All solenoid electrical connectors must face upward on installation. NOTE: ^ All shift solenoids are interchangeable. ^ If the TCC valve came out during disassembly, use caution when installing the torque converter clutch solenoid. Install the SSB, SSD, TCC and EPC solenoids. 1. Install the TCC solenoid. 2. Install the SSB and SSD solenoids. 3. Install the EPC solenoid. 17. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp and the screw. 1. Position the solenoid clamp on the main control valve body. 2. Install the screw. 18. CAUTION: The shift solenoid electrical terminals must face up on installation. NOTE: The shift solenoids are interchangeable. Install the SSA and the SSC shift solenoids. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6078 19. Install the solenoid clamp and the screw. 1. Position the solenoid clamp on the main control valve body. 2. Install the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6079 Valve Body: Service and Repair Removal and Installation Main Control Valve Body Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Place a drain pan under the transmission fluid pan. 4. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6080 5. Drain transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained remove the front two transmission fluid pan screws. 6. NOTE: If a transmission has been disassembled to install new parts and the valves in the main control valve body stick repeatedly from foreign material, the torque converter must be removed and cleaned by using a suitable torque converter/fluid cooler cleaner. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 7. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 8. Unclip main control valve body wire harness. 1. Lift up on wire harness guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6081 9. Disconnect the six solenoid electrical connectors. 1. Disconnect the SSA, SSB, SSC and SSD electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 10. Remove the manual control valve detent lever spring. 1. Remove the manual control valve detent lever spring screw. 2. Remove the manual control valve detent lever spring. 11. Remove the low/reverse servo. 1. Remove the low/reverse servo cover screws. 2. Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket. 12. Remove the low/reverse band servo piston and rod. 13. CAUTION: Support the main control valve body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6082 Do not remove the two (gold) screws specified. 14. CAUTION: Support the main control valve body. Remove the screws. 15. Remove the main control valve body. Installation 1. Install the special tool into the transmission case. 2. NOTE: Make sure main control to case gasket is correctly aligned. Install new main control to case gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6083 3. Position the main control valve body with the two special tools as a guide. 4. NOTE: The main control valve body screws will be tightened in later steps. Loosely install four M6 x 45 mm (1.8 inch) screws. 5. NOTE: The main control valve body screws will be tightened in later steps. Loosely install two M6 x 35 mm (1.4 inch) screws. 6. Remove the special tools. 7. NOTE: The main control valve body screws will be tightened in later steps. Loosely install the M6 x 30 mm (1.2 inch) screw. 8. NOTE: The main control valve body screws will be tightened in later steps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6084 Loosely install the sixteen M6 x 40 mm (1.6 inch) main,control valve body screws. 9. Tighten the main control valve body screws in the sequence shown. 10. Install the manual control valve detent lever spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6085 11. Install the low/reverse band servo piston and rod. 12. Install the low/reverse band servo cover. 1. Install the low/reverse band servo cover and gasket. 2. Loosely install the low/reverse servo piston cover screws. 13. Tighten the servo cover screws in the sequence shown. 14. Connect the six solenoid electrical connectors. 1. Connect SSA, SSB, SSC, and SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electronic Pressure Control (EPC) solenoid electrical connector. 15. CAUTION: Excessive pressure may break the locating pins. Install the main control valve body wire harness. ^ Align the retaining pins to the holes in the solenoid clamps and press in the main control valve body wire harness guide and protector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6086 16. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. 17. Install the transmission fluid pan. 1. Position anew transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. 18. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 19. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 20. Lower the vehicle. 21. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6087 condition and will eventually return to normal operating condition. Connect the battery ground cable. 22. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair Wiring Harness: Service and Repair Internal Harness Service Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect vehicle harness from transmission case (16 pin) connector. 4. Drain the transmission fluid. 5. NOTE: The main control assembly does not need to be removed. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Remove main control valve body wire loom. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 6091 7. Disconnect the solenoid electrical connectors. 1. Disconnect the SSA, SSB, SSC, and the SSD electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 8. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of their bore. This may damage the solenoid or converter modulator valve. ^ CAUTION: Shift solenoids may pop out of their bore. This may damage the solenoids. Remove the EPC and SSB solenoids. 1. Remove the solenoid clamp screws. 2. Remove the solenoid clamp. 3. Remove the EPC and SSB solenoids. 9. CAUTION: Do not pry on the other wires or damage the connector case surface. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector from the transmission case (16 pin) electrical connector. 1. Disconnect the TSS sensor electrical connector. 2. Remove from the TSS sensor wire locator. 10. CAUTION: Do not overstretch the retaining spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 6092 Remove the transmission case (16 pin) electrical connector retaining spring. 11. CAUTION: Do not damage the connector or harness. Remove the transmission case (16 pin) electrical connector. ^ Compress the tabs on the transmission case (16 pin) electrical connector. ^ Push the transmission case (16 pin) electrical connector out of transmission case. Installation 1. NOTE: ^ Make sure the tab is in the lock position. ^ Install new O-rings on the transmission case (16 pin) electrical connector. Install the transmission case (16 pin) electrical connector. ^ Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 6093 2. Press the transmission case (16 pin) electrical connector through the case until a click is heard. 3. CAUTION: Align the slot on the TSS Sensor electrical connector with the slot in the 16 pin case connector. Install the TSS sensor wire. 1. Install TSS sensor wire into (16 pin) case connector. 2. Install TSS sensor wire into the locator. 4. CAUTION: Do not overstretch the retaining spring. Install the transmission case (16 pin) electrical connector retaining spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 6094 5. Install the EPC and SSB solenoids. 6. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 7. Connect the SSA and SSC shift (SS) solenoid electrical connectors. 8. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors. 9. CAUTION: Excessive pressure may break the retaining pins. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 6095 Install the wire harness guide and protector. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the wire harness guide and protector. 10. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. 11. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 12. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 6096 13. Connect vehicle harness to transmission (16 pin) connector. Make sure lock is fully engaged. 14. Lower the vehicle. 15. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 16. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications O.S. Diameter (approximate) 258 mm I.S. Diameter (approximate) 173 mm Facing Area sq. See note 288 Cm 45 sq. inch Diaphragm spring Bellevile Compressed thickness 7.8 mm Lining material woven non-asbestos flywheel runout 0.13 mm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6101 Clutch Disc: Service and Repair Disc and Pressure Plate Special Tool(s) Removal 1. Remove the transmission. 2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur resulting in complete clutch release. Remove the bolts, clutch pressure plate and the clutch disc. ^ If the parts are to be reused, index-mark the clutch pressure plate to the flywheel. Installation 1. Lubricate the transmission input shaft pilot bearing. ^ Use front axle grease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6102 2. Adjust the clutch pressure plate. 1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely. 2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position. 3. Release the pressure on the fingers. The adjusting ring will stay in the reset position. 3. Using the special tool, position the clutch disc on the flywheel. 4. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal. Using the special tool, align the clutch disc and the clutch pressure plate. Install the bolts and tighten in a star pattern sequence. 5. Install the transmission. ^ Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Ford High Performance DOT3 Motor Vehicle Brake Fluid C6AZ-19542-AB ESA-M6C25-A, DOT3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage Clutch Master Cylinder: Customer Interest Clutch - Pedal Stays On Floor/Does Not Disengage Article No. 01-24-1 12/10/01 CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID LEAK FROM HYDRAULIC CLUTCH LINE FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or External Slave Cylinder. ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure for details. SERVICE PROCEDURE Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter pins. NOTE MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND F650-750. NOTE VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER) REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150. 1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave Cylinder (see previous notes) and the hydraulic line is disconnected or leaking. 2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder, External Slave Cylinder and system bleed procedure. 3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External Slave Cylinder. 4. Remove old quad seal from Master Cylinder and External Slave Cylinder. 5. Install new quad seal in Master Cylinder and External Slave Cylinder. 6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and External Slave Cylinder. 7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External Slave Cylinder). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6115 8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall. Labor Operation Claiming Chart Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7C522 39 OASIS CODES: 505200, 506000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage Clutch Master Cylinder: All Technical Service Bulletins Clutch - Pedal Stays On Floor/Does Not Disengage Article No. 01-24-1 12/10/01 CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID LEAK FROM HYDRAULIC CLUTCH LINE FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or External Slave Cylinder. ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure for details. SERVICE PROCEDURE Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter pins. NOTE MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND F650-750. NOTE VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER) REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150. 1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave Cylinder (see previous notes) and the hydraulic line is disconnected or leaking. 2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder, External Slave Cylinder and system bleed procedure. 3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External Slave Cylinder. 4. Remove old quad seal from Master Cylinder and External Slave Cylinder. 5. Install new quad seal in Master Cylinder and External Slave Cylinder. 6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and External Slave Cylinder. 7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External Slave Cylinder). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6121 8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall. Labor Operation Claiming Chart Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7C522 39 OASIS CODES: 505200, 506000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 6122 Clutch Master Cylinder: Specifications Clutch master cylinder reservoir bolts 18 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 6123 Clutch Master Cylinder: Service and Repair 1mClutch Master Cylinder/Reservoir Special Tools Removal and Installation 1. Raise and support the vehicle. 2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. 3. Lower the vehicle. 4. Disconnect the Clutch Pedal Position (CPP) switch electrical connector. 5. Disconnect the clutch master cylinder rod from the clutch pedal arm. ^ Remove and discard the clutch master cylinder push rod bushing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 6124 6. Remove the CPP switch. ^ Pinch the lock tabs and pull the clip forward. ^ Rotate and snap the CPP switch from the clutch master cylinder rod. 7. Remove the reservoir. 8. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 9. Unclip the hydraulic line-to-frame retainer. 10. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 6125 Unlock and remove the clutch master cylinder assembly. ^ Twist the clutch master cylinder clockwise 45 degrees to unlock it from the support bracket. ^ Remove the reservoir, the hydraulic line and the clutch master cylinder as an assembly. ^ Install a new clutch master cylinder push rod bushing. 11. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. To install, reverse the removal procedure. ^ Bleed the clutch hydraulic system. ^ Rotate the clutch master cylinder 45 degrees counterclockwise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Slave Cylinder: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage Clutch Slave Cylinder: Customer Interest Clutch - Pedal Stays On Floor/Does Not Disengage Article No. 01-24-1 12/10/01 CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID LEAK FROM HYDRAULIC CLUTCH LINE FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or External Slave Cylinder. ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure for details. SERVICE PROCEDURE Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter pins. NOTE MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND F650-750. NOTE VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER) REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150. 1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave Cylinder (see previous notes) and the hydraulic line is disconnected or leaking. 2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder, External Slave Cylinder and system bleed procedure. 3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External Slave Cylinder. 4. Remove old quad seal from Master Cylinder and External Slave Cylinder. 5. Install new quad seal in Master Cylinder and External Slave Cylinder. 6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and External Slave Cylinder. 7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External Slave Cylinder). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Slave Cylinder: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6134 8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall. Labor Operation Claiming Chart Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7C522 39 OASIS CODES: 505200, 506000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Slave Cylinder: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage Clutch Slave Cylinder: All Technical Service Bulletins Clutch - Pedal Stays On Floor/Does Not Disengage Article No. 01-24-1 12/10/01 CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID LEAK FROM HYDRAULIC CLUTCH LINE FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or External Slave Cylinder. ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure for details. SERVICE PROCEDURE Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter pins. NOTE MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND F650-750. NOTE VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER) REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150. 1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave Cylinder (see previous notes) and the hydraulic line is disconnected or leaking. 2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder, External Slave Cylinder and system bleed procedure. 3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External Slave Cylinder. 4. Remove old quad seal from Master Cylinder and External Slave Cylinder. 5. Install new quad seal in Master Cylinder and External Slave Cylinder. 6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and External Slave Cylinder. 7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External Slave Cylinder). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Slave Cylinder: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6140 8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall. Labor Operation Claiming Chart Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7C522 39 OASIS CODES: 505200, 506000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > Page 6141 Clutch Slave Cylinder: Specifications Clutch slave cylinder bolts 15 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > Page 6142 Clutch Slave Cylinder: Service and Repair Slave Cylinder Removal 1. Remove the transmission. 2. NOTE: Inspect the clutch housing for traces of fluid. If brake fluid is visible, install a new clutch slave cylinder. Remove the clutch slave cylinder. 1. Remove the bolts. 2. Remove the clutch slave cylinder. 3. Inspect the clutch slave cylinder for the following: ^ Worn or damaged boot. ^ Leaking fluid. ^ Worn or damaged bearing. 4. Inspect the clutch release bearing as follows: ^ Rotate the outer race while applying pressure. If the bearing rotation is rough, install a new clutch slave cylinder. ^ Inspect for wear or damage. ^ If wear pattern is continuous (not segmented) and the wear appears to be deep in bearing face, install a new clutch slave cylinder. Installation 1. To install, reverse the removal procedure. ^ Position the clutch slave cylinder to the transmission and install the bolts. 2. Install the transmission. 3. Bleed the clutch hydraulic system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage Hydraulic Hose: Customer Interest Clutch - Pedal Stays On Floor/Does Not Disengage Article No. 01-24-1 12/10/01 CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID LEAK FROM HYDRAULIC CLUTCH LINE FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or External Slave Cylinder. ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure for details. SERVICE PROCEDURE Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter pins. NOTE MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND F650-750. NOTE VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER) REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150. 1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave Cylinder (see previous notes) and the hydraulic line is disconnected or leaking. 2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder, External Slave Cylinder and system bleed procedure. 3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External Slave Cylinder. 4. Remove old quad seal from Master Cylinder and External Slave Cylinder. 5. Install new quad seal in Master Cylinder and External Slave Cylinder. 6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and External Slave Cylinder. 7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External Slave Cylinder). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6151 8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall. Labor Operation Claiming Chart Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7C522 39 OASIS CODES: 505200, 506000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage Hydraulic Hose: All Technical Service Bulletins Clutch - Pedal Stays On Floor/Does Not Disengage Article No. 01-24-1 12/10/01 CLUTCH - CLUTCH PEDAL STAYS ON FLOOR-NOT ABLE TO DISENGAGE CLUTCH - FLUID LEAK FROM HYDRAULIC CLUTCH LINE FORD: 2001 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 ISSUE Some vehicles may exhibit a condition of not being able to disengage clutch as the clutch pedal is stroked or the clutch pedal remains on floor. This may be caused by a roll pin that is loose or protruding and no longer securing the clutch hydraulic line to the Clutch Master Cylinder or External Slave Cylinder. ACTION Check to insure clutch hydraulic line is connected to the Master Cylinder and External Slave Cylinder and the roll pin is not loose or protruding outside the cylinder body. Check for the proper amount of fluid in reservoir. It the hydraulic line is not connected to the Master Cylinder or External Slave Cylinder and no fluid is present in reservoir, refer to the following Service Procedure for details. SERVICE PROCEDURE Use Service kit part number 2C3Z-7C522-AA. kit includes: 2 roll pins, 2 quad seals and 2 cotter pins. NOTE MASTER CYLINDERS AND EXTERNAL SLAVE CYLINDERS SHOULD BE SERVICED AT THE SAME TIME. VEHICLE LINES AFFECTED ARE ESCAPE, SUPER DUTY F-SERIES AND F650-750. NOTE VEHICLE LINES EQUIPPED WITH AN INTERNAL CSC (CONCENTRIC SLAVE CYLINDER) REQUIRE ONLY THE MASTER CYLINDER TO BE SERVICED. VEHICLE LINES AFFECTED ARE EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER AND F150. 1. Confirm if roll pin is dislodged at clutch hydraulic system Master Cylinder and/or External Slave Cylinder (see previous notes) and the hydraulic line is disconnected or leaking. 2. If so, refer to Workshop Manual (Section 308) for instructions on removing Master Cylinder, External Slave Cylinder and system bleed procedure. 3. Use an 1/8" punch and small hammer to remove roll pin from Master Cylinder and External Slave Cylinder. 4. Remove old quad seal from Master Cylinder and External Slave Cylinder. 5. Install new quad seal in Master Cylinder and External Slave Cylinder. 6. Reconnect hydraulic line and use a hammer to install a new roll pin at the Master Cylinder and External Slave Cylinder. 7. Install a cotter pin through the center of each roll pin and secure (Master Cylinder and External Slave Cylinder). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 01-24-1 > Oct > 01 > Clutch - Pedal Stays On Floor/Does Not Disengage > Page 6157 8. Refer to Workshop Manual (Section 308) for bleed procedure and reinstall. Labor Operation Claiming Chart Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7C522 39 OASIS CODES: 505200, 506000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Page 6158 Hydraulic Hose: Tools and Equipment Clutch Line Fork AST tool# 8008 Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford Aerostar, Bronco II, Explorer, F150 and Ranger. - For R and R of Hydraulic Clutch Lines - Applicable to Ford Models with Manual Transmissions - Steel Construction - Black-Oxide Finish Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Clutch pedal type suspended Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 6162 Clutch Pedal Assembly: Service and Repair Clutch Pedal Removal and Installation NOTE: The clutch pedal is serviced with the brake pedal as an assembly only. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Bearing Special Tools Special Tool(s) Removal 1. Using the special tool, remove the transmission input shaft pilot bearing. 2. Inspect the transmission input shaft pilot bearing for: ^ misalignment and looseness in the flywheel. ^ needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration. ^ seal leakage. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 6169 1. NOTE: The transmission input shaft pilot bearing can only be installed with the seal facing the transmission. The transmission input shaft pilot bearing is pregreased and does not require additional lubrication. A new transmission input shaft pilot bearing must be installed whenever it is removed. Using a soft-face hammer and the special tool, install the transmission input shaft pilot bearing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Clutch pressure plate bolts 24 ft. lbs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6173 Pressure Plate: Service and Repair "For information regarding this component please refer to Clutch Disc MT Service and Repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case Differential Case: Service and Repair Case Differential Case Special Tools Special Tool(s) Removal 1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage. 3. Rotate the differential assembly to check for roughness indicating bearing/gear damage. 4. NOTE: There is a space between the anti-lock speed sensor ring and the differential ring gear for measuring the differential ring gear backface runout. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6179 Using a suitable dial indicator and the special tool, measure and note the differential ring gear backface runout. 5. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions. Remove the bearing caps. 1. Remove the bolts. 2. Remove the bearing caps. 6. WARNING: Do not allow the differential assembly to fall. CAUTION: Place a wood block between the pry bar and the differential housing to protect the machined surface from damage. Using a pry bar and a wood block, remove the differential assembly from the differential housing. 7. Remove the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6180 8. CAUTION: ^ Do not damage the differential ring gear bolt hole threads. ^ If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during installation. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. 9. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: Drive Pinion, Differential Case and Ring Gear-Conventional or Differential Case and Ring Gear-Traction-Lok, or to Installation in this procedure. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout. 10. Position the differential assembly, including the differential bearing cups and differential bearing shims, in the differential housing. Install the bearing caps and the bolts. 11. Position the special tool. 1. Rotate the differential case to verify that the differential bearings have seated correctly. 2. Position the special tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6181 12. Measure and note the differential case runout. ^ If the runout does not exceed the specification, install a new differential ring gear and pinion. ^ If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Proceed as follows. 13. Using the special tools, remove the differential bearings. 14. Using the special tool, install the new differential bearings. 15. Position the differential assembly, including the differential bearing cups and differential bearing shims in the differential housing. Tighten bearing caps to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6182 16. Position the special tool. 1. Rotate the differential case to verify that the differential bearings have seated correctly. 2. Position the special tool. 17. Measure the differential case runout. ^ If the runout does not exceed the specification, use the new differential bearings for assembly. ^ If the runout exceeds the specification, install a new differential case. Installation All vehicles 1. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6183 2. Install the bolts. ^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads. 3. With the pinion depth set and pinion installed, place the differential assembly in the differential housing. 4. Install a differential bearing shim on the left side. 5. CAUTION: Always install the bearing caps in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly. Install the left bearing cap and loosely install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6184 6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. 8. Rotate the differential case to make sure it turns freely. Measuring backlash Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6185 9. Using the special tools, measure and note the differential ring gear backlash. ^ If backlash is within the specification, refer to Backlash within specification. The specification shown is the full allowable range. ^ If a zero backlash condition occurs, refer to Zero backlash. ^ If backlash is not within the specification, refer to Backlash not within specification. 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash. 11. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim accordingly. ^ If backlash is not within the specification,increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6186 12. Rotate the differential assembly several times to verify that the differential bearings seated correctly. 13. Using the special tools, recheck the backlash. ^ If backlash is within the specification, refer to Measuring backlash. ^ Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification. ^ The specification shown is the full allowable range. Backlash within specification 14. Remove the bolts and the bearing caps. 15. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown. 16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6187 17. Install the bearing caps and bolts. 18. Using the special tools, recheck the backlash. ^ The specification shown is the full allowable range. 19. Install the axle shafts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6188 Differential Case: Service and Repair Differential Case and Ring Gear -Conventional Differential Case and Ring Gear-Conventional Special Tools Special Tool(s) Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. 3. CAUTION: ^ Do not damage the differential ring gear bolt hole threads. ^ If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6189 Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. 4. Using the special tools, remove the differential bearings, if necessary. 5. Remove the bolt. 6. Remove the differential pinion shaft. 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6190 8. Remove the differential side gears and differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals. ^ Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Position the differential side gear thrust washers on the differential side gears. 3. Position the differential side gear and thrust washer assemblies in the differential case. 4. Lubricate and assemble the differential pinion thrust washers and differential pinion gears. ^ Use SAL 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6191 5. Engage the differential pinion gears opposite the differential side gears. 6. Rotate the differential pinion gears to align with the differential pinion shaft bore. 7. Insert the differential pinion shaft. ^ Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case. 8. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install a new bolt finger-tight. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6192 9. Using the special tool, install the new differential bearings. 10. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. 11. Install the bolts. ^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads. 12. Install the differential assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6193 Differential Case: Service and Repair Differential Case and Ring Gear -Traction-LOK Differential Case and Ring Gear-Traction-Lok Special Tool(s) Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. 3. CAUTION: ^ Do not damage the bolt hole threads. ^ If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6194 4. Using the special tools, remove the differential bearings. 5. Remove the bolt and remove the differential pinion shaft. 6. WARNING: Due to the spring tension, use care when removing the differential clutch spring. Failure to follow these instruction can result in personal injury. Remove the differential clutch spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6195 7. Remove the differential gears. 1. Remove the two differential pinion gears. 2. Remove the two differential side gears. 3. Remove the two differential pinion thrust washers. 8. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence. Separate the differential clutch packs and shims from the differential side gears and tag them ^ Clean and inspect the remaining differential components for wear and damage and install new parts as necessary. 9. CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth. Clean and inspect the differential clutch packs for wear and damage and install new parts as necessary. Assembly 1. CAUTION: 118 ml (4 on) of the Additive Friction Modifier must be used in the axle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6196 Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes. ^ Use Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C11-A. 2. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the other. Assemble the differential clutch packs (without the shims) on their respective differential side gear. 3. CAUTION: Use the correct mandrel with the special tool. Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6197 4. Position the special tool hand-tight on top of the differential clutch pack. 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut. 7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. 8. Remove the special tool from the differential clutch pack and differential side gear assembly. 9. Install the shim(s) on the differential clutch pack and differential side gear assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6198 10. Install the differential side gear assemblies in the differential case. 11. Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case. 12. Using a soft-faced hammer, install the differential clutch spring. 13. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6199 Install the differential pinion shaft and install a new bolt finger-tight. 14. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear. ^ If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary. 15. Using the special tool, install the differential bearings. 16. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Case > Page 6200 17. Install the bolts. ^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to bolt threads. 18. Install the differential assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair Differential Cover: Service and Repair Differential Housing Cover Removal 1. Raise and support the vehicle. 2. NOTE: Empty the lubricant into a clean container for reuse. Remove the differential housing cover. 1. Remove the bolts and drain the lubricant from the differential housing. 2. Remove the differential housing cover. Installation 1. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to prevent contamination. Clean the gasket mating surfaces. 2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant. Apply a continuous bead of sealant to the differential housing cover. ^ Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A. 3. NOTE: If possible, allow one hour before filling the axle with lubricant to allow the silicone sealant to cure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Page 6204 Install the differential housing cover. 1. Position the differential housing cover. 2. Install the bolts. 4. CAUTION: For Traction-Lok(R) axles, first fill the rear axle with 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. NOTE: Service refill capacities are determined by filling the rear axle to the level shown. Fill the rear axle with 2.4 liters (5.0 pints) of lubricant and install the fill plug. ^ For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 5. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair Differential Axle Housing: Service and Repair Axle Housing Removal and Installation 1. NOTE: Make sure the parking brake control is fully released. Release the tension on the front parking brake cable and conduit. 1. Pull on the front parking brake cable and conduit until the parking brake pedal moves. 2. Insert a suitable retainer, such as a 5/32-inch drill bit, into the parking brake control to hold it in place so that the front parking brake cable and conduit stays slack. 2. Raise and support the vehicle. 3. Remove the axle shafts. 4. Mark the driveshaft flange and pinion flange for correct alignment during installation. 5. CAUTION: The driveshaft centering socket yoke fits tightly on the rear pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool to disconnect the yoke from the flange. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6208 Remove the four driveshaft retainer bolts and disconnect the driveshaft. Wire the driveshaft out of the way. 6. NOTE: ^ Do not disconnect the brake lines from the brake hose junction block. ^ Explorer Sport Trac is shown. Explorer Sport brake hose junction block is located on the LH side of the differential housing. Disconnect the brake hose junction block from the differential housing. 7. Disconnect the vent hose. 8. Disconnect the parking cable and conduit at the parking brake lever, if so equipped. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6209 9. Disconnect the vehicle speed sensor, if so equipped. 10. CAUTION: Pull the brake lines from the retaining clips. Remove the brake system. ^ Disconnect the rear brake drum backing plates, if equipped, and wire them out of the way. ^ Remove the rear brake discs and the rear disc brake calipers and wire the rear disc brake calipers aside. 11. Position a suitable jack under the rear axle housing and strap it securely in place. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6210 12. Disconnect the rear stabilizer bar at the links. 13. Remove the lower shock absorber nuts and bolts, and the front dampener shock absorber nuts and bolts, if equipped. 14. Remove the rear axle U-bolt assembly. 15. CAUTION: Be careful of obstructions and of causing damage to vehicle components when performing this step. Raise the differential housing off the rear springs and manipulate the differential housing from the vehicle. 16. CAUTION: ^ Be sure to align the driveshaft flange and the pinion flange index-marks. ^ The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To ensure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6211 To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ............................................................. 5.5-5.8 pints Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 6216 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Conventional ........................................................................................................................................ ..................................................................... 80W-90 Traction-Lok ..................................................... ...................................................................................................................................... 75W-140 Synthetic Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Dana Pinion Bearing: Specifications Pinion Bearing Preload (New Pinion Bearings) 15 - 30 in.lb Pinion bearing preload (original pinion Bearings) See note the reading must be 0.56 nm (5 lb-in) more than the intial reading taken during disassembly. Bolt Retaining The Universal Joint Retainer To The Pinion Flange 14 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Dana > Page 6221 Pinion Bearing: Specifications Pinion Bearing Preload (Used Pinion Bearings) 8 - 14 in.lb Pinion Bearing Preload (New Pinion Bearings) 16 - 29 in.lb Differential Bearing Cap Bolt 77 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair Pinion Flange: Service and Repair Drive Pinion Flange Special Tools Special Tool(s) Removal 1. Remove the rear wheel and tire assemblies. 2. CAUTION: Remove the brake drums to prevent brake drag during drive pinion bearing preload adjustment. Remove the brake system. 3. CAUTION: Index-mark the driveshaft flange and pinion flange for correct alignment during installation. Remove the four bolts. 4. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool to disconnect the yoke from the flange. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 6225 Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear axle pinion flange. 5. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the pinion through several revolutions. 6. CAUTION: Discard the nut after removing it. Install a new nut during installation. Use the special tool to hold the pinion flange while removing the nut. 7. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 6226 8. Using the special tool, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. ^ For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 3. Using the special tool, install the pinion flange. 4. Position the new nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 6227 5. CAUTION: ^ Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. ^ Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. ^ Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. ^ If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded. 6. CAUTION: Align the Index-marks. Install the four bolts. 7. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To ensure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. Tighten to specification. 8. Install the bake system. 9. Install the rear wheel and tire assemblies. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair Pinion Gear: Service and Repair Drive Pinion Special Tools(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6231 Removal 1. Remove the differential case. 2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the pinion flange. Remove the pinion flange. 3. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer. 4. Using gripping pliers and a hammer, remove the rear axle drive pinion seal. 5. Remove the rear axle drive pinion shaft oil slinger. 6. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the front pinion bearing and remove it through the rear of the differential housing. 7. Remove the drive pinion collapsible spacer and discard it. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6232 8. Using the special tool and a suitable press, remove the pinion bearing. 9. NOTE: Do not remove the pinion bearing cups from the differential housing unless the cups are damaged. Using the special tools, remove the outer pinion bearing cup. 10. Using the special tools, remove the inner pinion bearing cup. Installation 1. NOTE: This step and the following step show the preferred method for installing the pinion bearing cups. An alternate method is shown following these two steps. Position the special tools and the inner and outer pinion bearing cups in their respective bores. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6233 1. After placing the inner and outer pinion bearing cups in their bores, place the special tool on the inner pinion bearing cup. 2. Place the special tool on the outer pinion bearing cup. 3. Install the special tool. 2. Tighten the special tool to seat the pinion bearing cups into their bores. 3. NOTE: This step and the following step are alternate methods for installing the pinion bearing cups. Carry out these two steps if pinion bearing cup installation was not done in the previous steps. Using the special tools, drive the outer pinion bearing cup into the differential housing. 4. Using the special tools, drive the inner pinion bearing cup into the differential housing. 5. CAUTION: Always install new pinion bearings when installing new pinion bearing cups. NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup. Check that the cups have seated correctly in their bores. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6234 6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the following in the differential housing. 7. NOTE: This step duplicates final pinion bearing preload. Tighten the special tool to the specification shown. 8. NOTE: Offset the special tool to obtain an accurate reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6235 Rotate the special tool several half-turns to make sure the pinion bearings seat correctly and position the special tool as shown. 9. Install the special tool. 1. Position the special tool. 2. Install the bearing caps. 3. Install the bolts. 10. CAUTION: ^ Use only flat, clean drive pinion bearing adjustment shims. ^ Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. ^ After determining the correct shim thickness, remove the special tools. 11. Position the correct thickness drive pinion bearing adjustment shim and the pinion bearing on the drive pinion. Using a suitable press and the special tools, press the pinion bearing until it seats firmly on the pinion. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6236 12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. CAUTION: Installation without the correct tool can result in early seal failure. Install a new rear axle drive pinion seal. 1. Install the front pinion bearing. 2. Install the rear axle drive pinion shaft oil slinger. 3. Install the rear axle drive pinion seal on the special tool. 14. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. NOTE: Coat the rear axle drive pinion seal lips with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6237 15. From inside the differential housing, install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into the carrier bore. 16. Lubricate the pinion flange splines. ^ For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R)axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 17. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 18. Using the special tool, install the pinion flange. 19. Position the new nut. 20. CAUTION: ^ Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. ^ Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6238 Use the special tool to hold the pinion flange while tightening the nut. ^ Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. ^ For new pinion bearings, tighten the nut to specification. ^ For used pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. ^ For used pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded. 21. Install the differential case in the differential housing. 22. CAUTION: Be sure to align the driveshaft flange and the pinion flange index-marks. Install the four bolts. 23. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To ensure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. Tighten to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Differential Case and Ring Gear-Conventional Ring Gear: Service and Repair Differential Case and Ring Gear-Conventional Differential Case and Ring Gear-Conventional Special Tools Special Tool(s) Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. 3. CAUTION: ^ Do not damage the differential ring gear bolt hole threads. ^ If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6243 Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. 4. Using the special tools, remove the differential bearings, if necessary. 5. Remove the bolt. 6. Remove the differential pinion shaft. 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6244 8. Remove the differential side gears and differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals. ^ Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Position the differential side gear thrust washers on the differential side gears. 3. Position the differential side gear and thrust washer assemblies in the differential case. 4. Lubricate and assemble the differential pinion thrust washers and differential pinion gears. ^ Use SAL 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6245 5. Engage the differential pinion gears opposite the differential side gears. 6. Rotate the differential pinion gears to align with the differential pinion shaft bore. 7. Insert the differential pinion shaft. ^ Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case. 8. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install a new bolt finger-tight. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6246 9. Using the special tool, install the new differential bearings. 10. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. 11. Install the bolts. ^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads. 12. Install the differential assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Differential Case and Ring Gear-Conventional > Page 6247 Ring Gear: Service and Repair Differential Case and Ring Gear-Traction-LOK "For information regarding this component please refer to Differential Case Service and Repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair Seals and Gaskets: Service and Repair Drive Pinion Seal Special Tools Special Tool(s) Removal 1. Remove the pinion flange. 2. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer. 3. Using gripping pliers and a hammer, remove the seal. Installation 1. Coat the new rear axle drive pinion seal lips with lubricant. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: ^ Installation without the correct tool can result in early seal failure. ^ If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 6251 Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Locations Axle Shaft: Locations Front Drive Halfshaft and Joint Assembly Part 1 of 2 Part 2 of 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Locations > Page 6257 Axle Shaft: Service and Repair Axle Shaft Removal NOTE: In this procedure, drum brake is shown. Disc brake is similar. 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Remove the brake system. ^ Remove the brake drum. ^ Remove the brake discs and rear disc brake calipers. 4. Remove the differential housing cover and drain the lubricant. 5. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Remove the differential pinion shaft. 1. Remove and discard the bolt. 2. Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Remove the U-washer. 1. Push the axle shaft inboard. 2. Remove the U-washer. 7. CAUTION: Do not damage the wheel bearing oil seal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Locations > Page 6258 Remove the axle shaft. Installation 1. Lubricate the lip of the wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Do not damage the wheel bearing oil seal. Install the axle shaft. 3. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Install the U-washer. 1. Position the U-washer on the button end of the axle shaft. 2. Pull the axle shaft outward. 4. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft. 1. Align the bolt hole in the differential pinion shaft with the bolt hole in the case. 2. Install the new bolt. 5. Install the brake system. ^ Install the brake drum. ^ Install the brake discs and calipers. 6. Install the differential housing cover and fill the differential housing with the specified lubricant. 7. Install the rear wheel and tire assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Locations > Page 6259 8. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Seals and Gaskets: Service and Repair Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Special Tools Special Tool(s) Removal 1. Remove the axle shaft. 2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 6264 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 6265 Seals and Gaskets: Service and Repair Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Special Tool(s) Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 6266 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications - Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 6270 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford Wheel Bearing: Service and Repair Ford Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Special Tools Special Tool(s) Removal 1. Remove the axle shaft. 2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford > Page 6273 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Special Tool(s) Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford > Page 6274 NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications - Tighten the spindle nut while rotating the brake disc and hub. - Loosen the spindle nut. - Tighten the spindle nut while rotating the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise Drive/Propeller Shaft: Customer Interest A/T - 5R55E 1st/2nd Gear Whining Noise Article No. 02-22-2 11/11/02 ^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 5R55E TRANSMISSION AND 4.0L ENGINE ONLY ^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002, equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary assemblies and/or the driveshaft. ACTION Verify that only these conditions exist and no DTCs are present. If other conditions are present and DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using the chart provided, select the parts that need to be replaced. NOTE IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED. SERVICE PROCEDURE Gear Whine Service Procedure 1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need to be replaced, refer to Application and Component replacement chart shown. 2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate Workshop Manual section for driveshaft removal/replacement. 3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual, Section 307-01, Transmission Removal procedures, remove the transmission. 4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement chart. NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 6288 NOTE BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE. 5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly (7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond the Reverse Planetary assembly. 6. Using the appropriate Transmission Assembly procedures, assemble the transmission and install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service Forward Planetary Assembly (XL2Z-7A398-AA). 7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission Installation procedures, install transmission. 8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the appropriate application listed. 9. Verify repair. Clear DTCs. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022202A Replace Transmission 5.5 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2 022202B Replace Transmission 7.0 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4 022202C Replace Driveshaft 0.4 Hr. Only 2002-2003 Explorer Sport Trac 4x2 DEALER CODING CONDITION BASIC PART NO. CODE 7A398 42 OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 6289 DISCLAIMER Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise Drive/Propeller Shaft: All Technical Service Bulletins A/T - 5R55E 1st/2nd Gear Whining Noise Article No. 02-22-2 11/11/02 ^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 5R55E TRANSMISSION AND 4.0L ENGINE ONLY ^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002, equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary assemblies and/or the driveshaft. ACTION Verify that only these conditions exist and no DTCs are present. If other conditions are present and DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using the chart provided, select the parts that need to be replaced. NOTE IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED. SERVICE PROCEDURE Gear Whine Service Procedure 1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need to be replaced, refer to Application and Component replacement chart shown. 2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate Workshop Manual section for driveshaft removal/replacement. 3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual, Section 307-01, Transmission Removal procedures, remove the transmission. 4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement chart. NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 6295 NOTE BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE. 5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly (7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond the Reverse Planetary assembly. 6. Using the appropriate Transmission Assembly procedures, assemble the transmission and install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service Forward Planetary Assembly (XL2Z-7A398-AA). 7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission Installation procedures, install transmission. 8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the appropriate application listed. 9. Verify repair. Clear DTCs. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022202A Replace Transmission 5.5 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2 022202B Replace Transmission 7.0 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4 022202C Replace Driveshaft 0.4 Hr. Only 2002-2003 Explorer Sport Trac 4x2 DEALER CODING CONDITION BASIC PART NO. CODE 7A398 42 OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 6296 DISCLAIMER Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6297 Drive/Propeller Shaft: Diagrams Driveshaft Rear Part 1 of 2 Part 2 of 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Drive/Propeller Shaft: Service and Repair Front Driveshaft-Front Removal and Installation 1. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the front axle pinion flange and the front driveshaft. 3. Remove the skid plate. 4. Index-mark the front output shaft assembly and the front driveshaft Constant Velocity (CV) joint. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front > Page 6300 5. Remove and discard the bolts and washers. 6. Remove and discard the bolts and universal joint retainers. 7. CAUTION: ^ Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear. ^ Tape the bearing cups to the driveshaft to prevent them from falling off of he spider. NOTE: The front driveshaft CV joint is not repairable. Remove the driveshaft. 8. NOTE: ^ Install the driveshaft with new bolts and washers and new bolts and universal joint retainers. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. ^ When installing the front driveshaft, always connect it to the axle first and then connect it to the transfer case. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front > Page 6301 Drive/Propeller Shaft: Service and Repair Rear Driveshaft-Rear Removal and Installation 1. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the driveshaft flange and the rear axle pinion flange. 3. Remove the driveshaft. 1. Remove and discard the four bolts, and disconnect the driveshaft from the rear axle pinion flange. 2. Lower the driveshaft, and slide it rearward off of the transmission output shaft. ^ Plug the extension housing to prevent fluid loss. 4. NOTE: Install the driveshaft with new bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair Slip Yoke: Service and Repair Driveshaft Slip Yoke Special Tools Special Tool(s) Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Remove the driveshaft slip-yoke boot. 1. Index-mark the driveshaft and the driveshaft slip-yoke. 2. Cut and discard the driveshaft slip-yoke boot clamps. 3. Separate the driveshaft slip-yoke from the splined stub shaft, and remove the driveshaft slip-yoke boot. ^ Inspect the driveshaft slip-yoke boot for damage and discard it if necessary. 3. Inspect the lubricant for contamination. If contaminated, inspect the stub shaft and driveshaft slip-yoke for wear. Discard the driveshaft if necessary. Assembly 1. Position the small driveshaft slip-yoke boot clamp on the splined stub shaft. 2. Position the end of the driveshaft slip-yoke boot with the smaller diameter opening on the splined stub shaft and slide the boot on the shaft as far as it will travel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair > Page 6305 3. Using the special tool, crimp the small driveshaft slip-yoke boot clamp. 4. CAUTION: Align the index marks made during disassembly. Install the driveshaft slip-yoke. 1. Lubricate the stub shaft splines with approximately 10 grams (0.24 oz) of lubricant, and pull the driveshaft slip-yoke boot towards the driveshaft. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. Position the large driveshaft slip-yoke boot clamp. 3. Align the index marks made during disassembly, and install the driveshaft slip-yoke. 5. Set the driveshaft assembled length to specification. 1. Remove any excess grease from the driveshaft slip-yoke surfaces. 2. Position the driveshaft slip-yoke boot in the driveshaft slip-yoke boot groove. 3. Set the driveshaft assembled length to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair > Page 6306 ^ Measure from the driveshaft weld to the end of the driveshaft slip-yoke. Set the assembled length to specification by moving the driveshaft slip-yoke inward or outward as necessary. 4. Bleed air from the driveshaft slip-yoke boot. 6. Using the special tool, crimp the large driveshaft slip-yoke boot clamp. 7. Install the driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation Universal Joints The universal joints are: ^ lubed-for-life design and require no lubrication. ^ equipped with nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearing and improve grease movement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke Universal Joint: Service and Repair Flange Yoke Driveshaft Universal Joint-Flange Yoke Special Tools Special Tool(s) Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench, being careful not to damage the tube. 3. NOTE: If components are not marked and installed correctly, driveline imbalance can occur. Index-mark the positions of the driveshaft components. 4. Clamp the U-Joint tool in a vise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6312 5. Remove all four of the snap rings. 6. Remove the driveshaft flange yoke. 1. Position the driveshaft flange yoke in the U joint tool. 2. Press out a bearing cup. 3. Remove the driveshaft flange yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft flange yoke. 7. Remove the spider. 1. Reposition the driveshaft in the U-Joint tool. 2. Press out the bearing cup. 3. Rotate the driveshaft. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the spider. 8. Clean the yoke area at the end of the driveshaft. Assembly 1. NOTE: Universal joint kits are to be installed as complete assemblies only. Do not mix components from other U-Joint kits. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6313 Install the spider. 1. Start a new bearing cup into the driveshaft yoke. ^ Check the needle bearings for correct positioning. 2. Position the new spider in the driveshaft yoke. 3. Position the driveshaft in the U-Joint tool. 4. Press the bearing cup to just below the snap ring groove. ^ Repeat for the other bearing cup. 2. Inspect the driveshaft flange yoke. Install new if necessary. 3. Install the driveshaft flange yoke. 1. Start a new bearing cup into the driveshaft flange yoke. ^ Check the needle bearings for correct positioning. 2. Position the driveshaft flange yoke. 3. Position the driveshaft in the U-Joint tool. 4. Press the bearing cup to just below the snap ring groove. ^ Repeat for the other bearing cup. 4. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-Joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U-Joint tool, and install the four snap rings. 5. NOTE: Do not strike the bearings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6314 Check the U-joints for freedom of movement. ^ If binding, strike the yoke with a brass or plastic hammer. 6. Install the driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6315 Universal Joint: Service and Repair Slip Yoke Driveshaft Universal Joint-Slip Yoke Special Tools Special Tool(s) Disassembly Initial disassembly 1. Remove the driveshaft. 2. CAUTION: Do not, under any circumstance, clamp the driveshaft assembly in the jaws of a vise or similar holding fixture.Denting or localizing fracture can result,causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Do not to damage the tube. 3. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance can occur. Index-mark the driveshaft components. 4. Remove all four of the snap rings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6316 5. Clamp the special tool in a vise. Bearing cup removal 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way. Remove the driveshaft slip-yoke. 1. Position the driveshaft slip-yoke in the special tool. 2. Press out a bearing cup. 3. Rotate the driveshaft slip-yoke 180 degrees. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft slip-yoke. Final disassembly 7. Repeat Bearing cup removal in this procedure to remove the remaining bearing cups and the spider from the driveshaft. 8. Clean the yoke area at each end of the driveshaft. Assembly Bearing cup installation 1. NOTE: Install the Universal Joint Kits as complete assemblies only. Do not mix components from other Kits. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Flange Yoke > Page 6317 Install the bearing cup. 1. Start a new bearing cup into the driveshaft yoke. ^ Check the needle bearings for correct positioning. 2. Position the new spider in the driveshaft yoke. 3. Using the special tool, press the bearing cup to just below the snap ring groove. 2. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-Joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the special tool, and install the snap ring. Opposite bearing cup installation 3. Repeat Bearing cup installation in this procedure to install the bearing cup and the snap ring on the opposite side of the driveshaft yoke. Slip-yoke installation 4. Inspect the driveshaft slip-yoke. Install a new yoke, if necessary. 5. Repeat Bearing cup installation in this procedure to install the driveshaft slip-yoke and the remaining new bearing cups and snap rings. Final assembly 6. NOTE: Do not strike the bearings. Check the U-joints for freedom of movement. ^ If binding, strike the yoke with a brass or plastic hammer. 7. Install the driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel Bolts Stage 1 10 ft. lbs. Stage 2 52 ft. lbs. Torque Converter-To-Flexplate Nuts 22-30 ft. lbs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel Bolts in the sequence shown in two stages. ^ Stage 1: ............................................................................................................................................ ........................................ 13 Nm (10 ft. lbs.). ^ Stage 2: ............................................................................................................................................ ........................................ 71 Nm (52 ft. lbs.). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Dowels - Flywheel Flywheel: Service and Repair Dowels - Flywheel Dowels, Flywheel Removal and Installation 1. NOTE: Take care not to damage the flywheel dowel holes or the surface areas around the flywheel dowel during removal. Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open hole and a pair of locking pliers where the flywheel dowel is installed in a blind hole. 2. NOTE: Care should be taken to drive the flywheel dowel squarely into place until it is fully seated and to not damage the surrounding surface areas. Install all flywheel dowels by driving them into place using a brass or plastic mallet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Dowels - Flywheel > Page 6326 Flywheel: Service and Repair Flywheel - Removal and Installation Flywheel Removal 1. Remove the transmission. 2. Remove the flywheel. 3. Clean and inspect the flywheel. Installation 1. NOTE: Special bolts are used for flywheel installation; do not use standard bolts. Install the flywheel. ^ Tighten the bolts in the sequence shown in two stages. ^ Stage 1: Tighten the bolts to 13 Nm (10 ft. lbs.). ^ Stage 2: Tighten the bolts to 71 Nm (52 ft. lbs.). 2. Install the transmission. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair Bell Housing: Service and Repair Dowels, Flywheel Housing to Block Removal and Installation 1. NOTE: Take care not to damage the flywheel housing to block dowel holes or the surface areas around the flywheel housing to block dowel hole during removal. Remove the flywheel housing to block dowels using a drift pin where the flywheel housing to block dowel is installed in an open hole and a pair of locking pliers where the flywheel housing to block dowel is installed in a blind hole. 2. NOTE: Care should be taken to drive the flywheel housing to block dowel squarely into place until it is fully seated without damaging the surrounding surface areas. Install all flywheel housing to block dowels by driving them into place using a brass or plastic mallet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Case Cover Bolts 12 - 16 ft.lb Case Plug 30 - 43 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Specifications Countershaft: Specifications Counter Lever Shaft Bolt 6 - 8 ft.lb Countershaft Locknut 94 - 144 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Drain plug 30 - 43 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair Extension Housing: Service and Repair Extension Housing Special Tools Special Tools Removal 1. Raise and support the vehicle. 2. Remove the drain plug and drain the transmission fluid. 3. NOTE: To maintain initial driveshaft balance, index-mark the driveshaft to the rear axle pinion flange so it can be installed in its original position. Remove and support the rear driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair > Page 6348 4. Using the special tool, support the transmission. ^ Secure the transmission with a strap. 5. Remove the six crossmember bolts. 6. Remove the nuts. 7. Remove the (RH) transmission mount bolt. 1. Remove the bolt. 2. Reposition the exhaust mounting bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair > Page 6349 8. Using the special tool, remove the extension housing seal. 9. Remove the extension housing. Installation 1. Install the extension housing. 2. Using the special tool, install the extension housing seal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair > Page 6350 3. Install the (RH) transmission mount bolt. 1. Position the exhaust bracket. 2. Install the bolt. 4. Position the crossmember and install the six bolts and nuts. 5. Remove High-Lift Transmission Jack. 6. Install the nuts. 7. NOTE: To maintain initial driveshaft balance, align the index marks on the driveshaft and the rear axle pinion flange made during removal. Install the rear driveshaft. 8. Install the drain plug. 9. Refill the transmission with the specified amount of fluid. ^ Use MERCON(R) Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON(R). 10. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications Fill Plug: Specifications Fill Plug 30 - 43 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6358 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6359 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 2.7 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 6362 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ............................................................. Mercon ATF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T > Component Information > Service and Repair Flywheel Gear: Service and Repair Ring Gear Removal WARNING: This procedure should be performed only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. 1. Remove the transmission. 2. Remove the clutch pressure plate and clutch disc. 3. Remove the flywheel. 4. CAUTION: ^ Do not heat the flywheel ring gear beyond 278° C (500° F). Use heat indicating crayons to prevent over heating. ^ Tap the flywheel ring gear evenly to prevent binding. Remove the flywheel ring gear from the flywheel, ^ Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear off the flywheel. Installation WARNING: This procedure should be performed only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. 1. CAUTION: ^ Do not heat the flywheel ring gear beyond 278° C (500° F). Use heat indicating crayons to prevent over heating. ^ Keep the torch moving to prevent hot spots. Evenly heat the flywheel ring gear. 2. Install the flywheel ring gear. ^ The bevel on the flywheel ring gear must face, the rear of the flywheel. ^ Use a brass drift. 3. Install the flywheel. 4. Install the clutch pressure plate and clutch disc. 5. Install the transmission. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6372 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6373 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 6376 Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6377 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6378 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6379 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Inner Gearshift Lever Boot Bolt 89 - 123 in.lb Outer Gearshift Lever Boot Screws 45 - 79 in.lb Gearshift Lever Bolt 20 - 29 ft.lb Gear Selector Interlock Bolts 72 - 89 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 6383 Shifter M/T: Service and Repair Shift Lever and Boot Removal and Installation 1. Raise the outer gearshift lever boot and console assembly to access the nut and eccentric stud that retains the upper gearshift lever to the lower gearshift lever. 1. Remove the two screws retaining the console to the floor. 2. Raise the outer gearshift lever boot and console assembly to access the nut and eccentric stud. 2. Remove the nut. 3. Install the nut on the LH side of the lever, then tighten the nut to remove the eccentric stud out of the gearshift lever. 4. Remove the upper gearshift lever and the outer gearshift lever boot and console assembly as an assembly. 5. CAUTION: Note the position of the vehicle identification tags on the top of the inner gearshift lever boot for correct installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 6384 If necessary, remove the four screws and the inner gearshift lever boot. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair Shift Boot: Service and Repair "For information regarding this component please refer to Shift lever Service and Repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Specifications Transmission Mount: Specifications Transmission Mount Bolts 64 - 81 ft.lb Transmission Mount Nuts 64 - 81 ft.lb Crossmember Bolts 39 - 53 ft.lb Crossmember Nuts 39 - 53 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6397 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6398 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 6401 Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6402 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6403 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6404 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6410 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6411 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1. Remove the cover. 2. Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6415 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6416 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6417 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6418 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6419 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6425 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6426 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 Transmission Speed Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Transmission Speed Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6450 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6451 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6452 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6478 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6485 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6486 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 6489 Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6490 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6491 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6492 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6499 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6500 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6501 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6524 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. NOTE: Transmissions with identification tag IL5P-DA or IL5P-EA only, will have adaptive shift strategy. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected, or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6525 Pressure Regulating Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6526 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6527 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6528 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts Retaining The Shift Lock Actuator To The Transmission Column Shift Selector Tube 80 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 6532 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1. Remove the screws and position the hood release handle out of the way. 2. Remove the two screws from the lower steering column opening finish panel. 3. Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 6533 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid Clamp Screws 53 - 71 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6537 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6538 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6539 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6540 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6563 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6564 Shift Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6565 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6566 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6567 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6571 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6572 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6573 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6596 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6597 Torque Converter Clutch Solenoid: Service and Repair Solenoids - Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. ^ Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6598 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: ^ The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. ^ Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6599 Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. ^ Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6600 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6611 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6612 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1. Remove the cover. 2. Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Screws 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6616 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6617 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6618 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6619 5. Remove the manual control outer lever nut and manual control outer lever. 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6620 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6626 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6627 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 Transmission Speed Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 Transmission Speed Sensor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6651 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6652 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6653 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6679 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed Sensor (OSS) Sensor Screw 71 - 97 in.lb Intermediate Shaft Speed Sensor (ISS) Sensor Screws 71 - 97 in.lb Turbine Shaft Speed (TSS) Sensor Screw 71 - 97 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6686 Transmission Speed Sensor: Locations Output Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6687 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 6690 Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6691 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6692 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6693 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 6699 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations > Page 6703 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON DTCB2607 May Be Set Article No. 01-6-1 04/02/01 ^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY FORD: 2001 EXPLORER ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607 may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp may remain on or may illuminate intermittently. This may be due to the ABS module remaining active when the engine is cranked and both blower motors are on. ACTION Replace the ABS module with an updated module if existing module is the original design, and check for proper circuit grounding. Refer to the following Service Procedure for details. SERVICE PROCEDURE It the ABS lamp is on intermittently: 1. Replace the ABS module. a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Test drive vehicle to verify repair. If the ABS lamp is on continuously: 1. Replace the ABS module. a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 3. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6712 b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 3. Verify if the vehicle is a 4X4 or 4X2. ^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded. ^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary. 4. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 5. b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 301000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON DTCB2607 May Be Set Article No. 01-6-1 04/02/01 ^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY FORD: 2001 EXPLORER ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607 may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp may remain on or may illuminate intermittently. This may be due to the ABS module remaining active when the engine is cranked and both blower motors are on. ACTION Replace the ABS module with an updated module if existing module is the original design, and check for proper circuit grounding. Refer to the following Service Procedure for details. SERVICE PROCEDURE It the ABS lamp is on intermittently: 1. Replace the ABS module. a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Test drive vehicle to verify repair. If the ABS lamp is on continuously: 1. Replace the ABS module. a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 3. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6718 b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 3. Verify if the vehicle is a 4X4 or 4X2. ^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded. ^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary. 4. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 5. b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 301000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6719 Electronic Brake Control Module: Specifications Control module bolts 13 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6720 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6721 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6722 Electronic Brake Control Module: Description and Operation Anti-Lock Brake Control Module NOTE: The new anti-lock brake control module must be reconfigured upon installation. The anti-lock brake control module is mounted to the HCU. It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and the necessary circuitry for their operation. The anti-lock brake control module monitors system operation during normal driving as well as during anti-lock braking. Anti-lock brake module operation is as follows: ^ Under normal driving conditions, the microprocessor produces short test pulses to the solenoid valves that check the electrical system without any mechanical reaction. ^ Impending wheel lock conditions trigger signals from the anti-lock brake control module that open and close the appropriate solenoid valves. This results in moderate pulsations in the brake pedal. During normal braking, the brake pedal feel will be identical to a standard brake system. Most faults that occur in the anti-lock brake system will be stored as a diagnostic trouble code (DTC) in the keep-alive memory of the anti-lock brake control module. The DTCs can be retrieved by following the on-board diagnostic procedures. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6723 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6724 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the electrical connectors. 3. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the anti-lock brake control module. 4. CAUTION: Once the new module is installed, the module configuration information may have to be entered. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Hydraulic control unit (HCU) to bracket bolts 71 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6728 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit The HCU consists of the following components: ^ brake pressure control valve block ^ pump motor New brake pressure control valve block and pump motor are installed as an assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6729 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6730 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the hydraulic control unit (HCU). 4. Remove the HCU. 1 Remove the bolts. 2 Remove the HCU. 5. If necessary, remove the anti-lock brake control module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6731 6. CAUTION: After the electronic hydraulic control unit is installed, it is necessary to bleed the hydraulic brake system. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Front Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 8.5 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Front > Page 6736 Wheel Speed Sensor: Specifications Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front > Page 6739 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6742 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6743 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 6744 Wheel Speed Sensor: Description and Operation Anti-Lock Brake Sensor NOTE: Any time an anti-lock brake sensor is removed, thoroughly clean the mounting surfaces. On front anti-lock brake sensors, apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. The anti-lock brake system uses three variable-reluctance sensors to determine vehicle speed. The anti-lock brake sensors operate on magnetic induction principle. As the teeth on the anti-lock brake sensor indicator rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and sent to the anti-lock brake control module through a twisted cable and shielded wiring harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control Wheel Speed Sensor: Service and Repair Rear Antilock Control Sensor-Rear Removal and Installation 1. Raise and support vehicle. 2. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. 3. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 6747 Wheel Speed Sensor: Service and Repair Sensor, Front Sensor-Front 4x2 Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front anti-lock brake sensor. 4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 6748 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor-Rear Removal and Installation NOTE: The rear anti-lock brake sensor indicator is attached to the differential case. For additional information, refer to Transmission and Drivetrain; Differential. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Disc brake caliper bleeder screw 15 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding Caliper WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6754 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Disc brake is shown, drum brake is similar. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6755 4. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6756 Brake Bleeding: Service and Repair Brake System Pressure Bleeding Pressure WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Disc brake is shown, drum brake is similar. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6757 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6758 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: This procedure only needs to be carried out if a new 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. NOTE: Disc brake is shown, drum brake is similar. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6759 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Repeat the bleed procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6760 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Master Cylinder Priming-In-Vehicle or Bench WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake component and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. 2. For bench priming, mount the brake master cylinder in a vise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6761 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, loosen the speed control pressure switch. 5. Slowly depress and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the brake pedal. 6. Tighten the speed control pressure switch. 7. Repeat the above three steps until no air bubbles are visible in the expelled fluid. 8. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 9. If necessary, install the brake master cylinder into the vehicle. 10. Remove the short brake tubes and install the master cylinder outlet tubes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6762 11. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 12. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 13. Tighten the outlet tube fitting at the HCU. 14. Repeat the above three steps until no air bubbles are visible in the expelled brake fluid. 15. Repeat the above four steps for the remaining master cylinder outlet tube. 16. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 17. Have an assistant pump and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6763 18. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 19. Tighten the master cylinder bleeder screw. 20. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 21. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Page 6764 Brake Bleeding: Tools and Equipment Special Tools Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake pedal bracket bolts and nuts 18 ft.lb Brake pedal bracket nuts 18 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6768 Brake Pedal Assy: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Brakes and Traction Control; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6769 Brake Pedal Assy: Service and Repair Brake Pedal and Bracket Removal and Installation All vehicles 1. NOTE: When removing the stoplight switch, retain the bushing and hairpin clip. They will be required for installation. Disconnect the brake booster push rod. 1 Remove the hairpin clip. 2 Separate the stoplight switch and the brake booster push rod from the brake pedal pin. 3 Remove the brake booster push rod bushing. Vehicles with manual transmission 2. Disconnect the clutch master cylinder push rod. 3. Disconnect the clutch pedal position switch (CPP). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6770 4. Remove the clutch master cylinder by rotating the clutch master cylinder 45 degrees clockwise. 5. Remove the bulkhead sound insulator. All vehicles 6. Remove the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6771 7. CAUTION: Support the brake master cylinder and power brake booster in the engine compartment. Remove the nuts and the brake pedal assembly. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper bleeder screw, rear 15 in.lb Caliper bleeder screw, front 15 in.lb Front disc brake caliper anchor plate bolts 72-97 ft.lb Disc brake caliper bolts 21-26 ft.lb Brake caliper bolts 20 ft.lb Caliper flow bolt 23-29 ft.lb Rear wheel disc brake adapter bolts 80 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Caliper Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Use of any other than approved DOT 3 brake fluid will cause damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not clamp the brake hose. The hose can be damaged. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6778 5. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers; connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Check the brake system for correct operation. Caliper Disassembly and Assembly Caliper Disassembly WARNING: Use of any brake fluid other than approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6779 CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25A. ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid. 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6780 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal 1. NOTE: 4x4 is shown, 4x2 is similar. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6781 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6782 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Caliper Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not clamp the brake hose. The hose can be damaged. Disconnect the brake hose. 1 Remove the bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-MlC171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6783 5. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Connect the brake hose and install the caliper flow bolt. Use new copper washers. 3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Verify correct brake operation. Caliper Disassembly and Assembly Caliper Disassembly WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6784 WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear disc brake piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear disc brake piston out to the block of wood. 4 Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6785 1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ cylinder bore ^ piston seal ^ rear disc brake piston ^ dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Rear Disc Brake Adapter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6786 Adapter Removal and Installation 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the bolts and the rear wheel disc brake adapter. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 6787 Brake Caliper: Tools and Equipment Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum thickness above the metal backing plate or rivets 0.10 in Brake hose bolt 23-29 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Pads Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Install a new pad if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 5. Remove the lower caliper bolt. 6. Rotate the disc brake caliper upward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6793 7. Remove the pads and the slippers. 1 Remove the pads. 2 Remove the stainless slippers. 8. NOTE: 4x2 is shown, 4x4 is similar. Inspect the brake disc. ^ If the brake disc is cracked, install a new brake disc. ^ If diagnosis has revealed vibration in the steering wheel, seat, or brake pedal while braking, machine the brake disc. Heavily scored brake discs, similar to that caused by linings worn to the backing plate, must also be machined. ^ Measure the brake disc for minimum thickness. ^ If the brake disc is not within specification, install a new brake disc. 9. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6794 1. NOTE: Use a suitable suction device to remove brake fluid from the master cylinder. NOTE: Clean the anchor plate and slipper surfaces. Install the slippers and the pads. 1 Install the slippers. 2 Install the pads. 2. NOTE: If installing new pads, the caliper pistons must be compressed using a C-clamp and a wooden block. Lower the brake fluid level in the master cylinder if required. Rotate the disc brake caliper downward. 3. Install the caliper bolt. 4. Install the wheel and tire assembly. 5. Check the brake system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6795 Brake Pad: Service and Repair Rear Pads Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. CAUTION: Install new pads if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination. Install new pads if worn to or past specification. 3. NOTE: It is not necessary to remove the rear wheel brake hose when carrying out this procedure. Remove the rear disc brake caliper. 4. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads. 5. Retract the caliper piston into the rear disc brake caliper. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6796 6. Remove and discard the slippers. 7. Inspect the brake disc. ^ If the brake disc is cracked, install a new brake disc. ^ If diagnosis has revealed vibration in the steering wheel, seat, or brake pedal while braking, machine the brake disc. Heavily scored brake discs, similar to that caused by linings worn to the backing plate, must also be machined. ^ Measure the brake disc for minimum thickness. ^ If the brake disc is not within specification, install a new brake disc. Installation 1. CAUTION: New stainless steel slippers must be installed when new brake pads are installed, even if the slippers appear undamaged. Make sure the slippers are correctly positioned with the slipper ends snug against the outboard end of the anchor plate rail. Clean the slipper mating surface, and install the new slippers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6797 2. CAUTION: Install new brake pads in full axle sets. Do not install new brake pads on only one side of the vehicle. Install the brake pads. 3. Install the rear disc brake caliper. 4. Verify correct brake operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc .............................................................................................................................................................. ........................................................ Min Thickness Front .................................................................................................................................................... ............................................. 0.9646 inch (24.50mm) Rear ..................................................................................................................................................... .................................................. 0.4331 inch (11mm) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 6802 Brake Rotor/Disc: Specifications Brake disc shield bolts 7-10 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor/Disc: Service and Repair Front Brake Disc Disc Removal All vehicles 1. Remove the front disc brake caliper anchor plate. 4x4 vehicles 2. NOTE: Match-mark the brake disc and hub. Remove the brake disc. 3. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc. Measure the brake disc and resurface as necessary. Install a new brake disc if beyond specification. 4x2 vehicles 4. NOTE: Match-mark the brake disc and hub. Remove the brake disc and hub as follows: 1 Remove the hub grease cap. 2 Remove the cotter pin. 3 Remove the nut retainer. 4 Remove the spindle nut. 5 Remove the front wheel outer bearing retainer washer. 6 Remove the outer front wheel bearing. 7 Remove the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6805 5. Remove the wheel hub grease seal and wheel bearing. 1 Remove the wheel hub grease seal. 2 Remove the wheel bearing. 6. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc. Measure the brake disc, and resurface as necessary. Install a new brake disc if beyond specification. Installation 4x4 vehicles 1. Position the brake disc to the wheel hub. ^ Use Metal Brake Parts Cleaner F6AZ-2C410-AB or equivalent to clean the brake disc. ^ Using match-marks, mount the brake disc on the hub. ^ Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the hub mounting surface to prevent future corrosion. 4x2 vehicles 2. Thoroughly clean and inspect the front wheel bearings and the brake disc and hub. ^ Use Metal Brake Parts Cleaner F6AZ-2C410-AB or equivalent. 3. Lubricate the front wheel bearings. ^ Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6806 4. Install a new wheel hub grease seal. 1 Install the inner front wheel bearing. 2 Install a new wheel hub grease seal. 5. Install the brake disc and hub. 1 Position the brake disc and hub. 2 Install the outer front wheel bearing. 3 Install the front wheel outer bearing retainer washer. 4 Install the spindle nut. 6. Tighten the spindle nut while rotating the brake disc and hub. 7. Loosen the spindle nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6807 8. Tighten the spindle nut while rotating the brake disc and hub. 9. Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. All vehicles 10. Install the front disc brake caliper anchor plate. Brake Disc Shield Shield-4x2 Removal and Installation 1. Remove the brake disc. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6808 2. Remove the bolts and the brake disc shield. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6809 Brake Rotor/Disc: Service and Repair Rear Brake Disc Disc Removal and Installation 1. NOTE: When removing the rear brake disc in this procedure it is not necessary to disconnect the hydraulic lines. Remove the rear disc brake caliper. 2. NOTE: If the rear brake disc binds on the rear parking brake shoe and linings, remove the adjustment hole access plug and retract the parking brake shoe and lining. Remove the rear brake disc. 3. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc. Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond specification. 4. To install, reverse the removal procedure. Brake Disc Shield Shield Removal 1. Remove the rear wheel disc brake adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6810 2. Remove the rear wheel disc brake shield. 1 Drill out the rivet, (if present). 2 Remove the rear wheel disc brake shield. Installation 1. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, a new rivet is not required. Seal the rivet hole with Clear Silicone Rubber F7AZ-19554-CA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. 2. Install the rear wheel disc brake adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Brake backing plate nuts 40-50 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 6815 Backing Plate: Service and Repair Backing Plate Removal and Installation 1. Remove the rear brake shoes and linings. 2. Pull back the parking brake cable spring and disconnect the parking brake lever. 3. Remove the axle shaft or the axle shaft and rear hub, if so equipped. 4. Compress the cable retainer and pull the parking brake rear cable and conduit from the brake backing plate. 5. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder. 6. Remove the four backing plate-to-axle flange nuts and bolts and the brake backing plate. 7. To install, reverse the removal procedure. 8. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications .............................................................................................................................................................. .............................................. Max Drum Diameter Rear ..................................................................................................................................................... ......................................... 11.0866 inch (281.60mm) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 6819 Brake Drum: Service and Repair Drum Removal and Installation WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a Brake/Clutch/Service Vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. WARNING: If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair are to be present in the area. WARNING: To reduce the possibility of uneven braking, always install new rear brake shoes and linings at both ends of an axle. NOTE: Make sure that the parking brake control is fully released. 1. Remove the wheel and tire assembly. 2. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result. NOTE: If the brake drum is rusted to the axle shaft pilot diameter, tap the center of the brake drum between the wheel studs. Remove the brake drum. 1 Remove and discard the spring nut. 2 Pull the brake drum off the axle shaft. 3. NOTE: If the brake drum will not come off, follow these steps. Loosen the brake shoe adjusting screw nut. 1 Using a screwdriver, move the brake shoe adjusting lever off the brake adjuster screw. 2 NOTE: Move the adjustment tool handle downward to loosen the brake shoe adjusting screw nut. Use the Brake Adjustment Tool to loosen the brake shoe adjusting screw nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 6820 4. Using the Brake Drum Micrometer, measure the brake drum inside diameter. ^ Install a new brake drum if the maximum inside diameter exceeds the specification molded on the brake drum. 5. NOTE: If adjusting the rear brakes. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 6821 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Lining minimum thickness 0.03 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6825 Brake Shoe: Adjustments Brake Drums Removed WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a Brake/Clutch/Service Vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair are to be present in the area. NOTE: After adjusting the rear brake shoes and linings, check the parking brake for correct operation. Make sure the parking brake cable equalizer operates freely. 1. Measure the brake drum inside diameter. ^ Use a brake adjustment gauge. 2. Adjust the rear brake shoes and linings. ^ Rotate the brake adjuster screw until the rear brake shoes and linings touch the tool. Brake Drums Installed 1. Raise and support the vehicle. 2. At the back of the brake backing plate, remove the brake adjusting hole cover. 3. Rotate the brake shoe adjusting screw nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6826 1 Using a screwdriver, move the brake shoe adjusting lever off the brake shoe adjusting screw nut. 2 NOTE: Move the adjustment tool handle upward to tighten the brake adjuster screw. Turn the brake shoe adjusting screw nut until the brake drum begins to drag. Then loosen the brake adjuster screw until the brake drum rotates freely. 4. Install a new brake adjusting hole cover. 5. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6827 Brake Shoe: Service and Repair Shoes Removal 1. Remove the brake drum. 2. Inspect the rear brake assembly for the following: ^ the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and rebuild as necessary. ^ the rear brake shoes and linings for contamination, and install new shoes and linings as necessary. ^ the rear brake shoes and linings for minimum thickness, above the backing plate or rivets, and install new as necessary. ^ the springs for heat discoloration, and install new as necessary. ^ the adjusting lever contact with the brake adjuster screw. 3. NOTE: To aid installation, note the locations of the short and long brake shoe retracting springs. Remove the brake shoe retracting springs. 1 Remove the long brake shoe retracting spring. 2 Remove the short brake shoe retracting spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6828 4. Remove the adjusting screw assembly. 1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever. 2 Remove the brake shoe adjusting lever cable. 3 Remove the cable guide. 4 Remove the adjusting lever return spring and the brake shoe adjusting lever. 5 Remove the brake shoe adjusting screw spring. 6 Remove the brake adjuster screw assembly. 5. NOTE: The parking brake link spring and the brake parking spring retainer will come off with the parking brake strut. Remove the brake shoe anchor pin guide plate, parking brake strut and the parking brake lever pin retainer. 6. Remove the rear brake shoes and linings. 1 Remove the brake shoe hold-down springs. 2 Remove the rear brake shoes and linings. 3 Remove the brake shoe hold-down spring pins. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6829 1. Clean and lubricate the brake backing plate. ^ Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 2. Attach the parking brake lever to the rear brake shoe and lining and secure the parking brake lever pin retainer. 3. Install the rear brake shoes and linings. 1 Position the rear brake shoes and linings. 2 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs. 4. Install the parking brake strut. 1 Install the parking brake link spring and the parking brake spring retainer on the parking brake strut. 2 Install the parking brake strut. 3 Install the brake shoe anchor pin guide plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6830 5. Install the short brake shoe retracting spring. 1 Place the brake shoe adjusting lever cable over the anchor pin, with crimped side in. 2 Install the short brake shoe retracting spring. 6. NOTE: Make sure the brake shoe adjusting lever cable is positioned in the cable guide groove. Install the long brake shoe retracting spring. 1 Install the cable guide. 2 Position the brake shoe adjusting lever cable in the cable guide groove. 3 Install the long brake shoe retracting spring. 7. Disassemble the brake adjuster screw assembly and apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 8. Assemble the brake adjuster screw assembly. 9. NOTE: To prevent incorrect installation, the socket end of each brake adjuster screw is stamped R or L. Install the brake adjuster screw assembly. 1 Position the brake adjuster screw assembly. 2 Install the brake shoe adjusting screw spring. 3 Position the brake shoe adjusting lever cable. 4 Position the adjusting lever return spring and the brake shoe adjusting lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6831 5 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever. 10. Test the operation of the automatic self-adjuster. 1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly. 2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut. 11. Adjust the brakes. 12. Install the brake drum. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6832 Brake Shoe: Tools and Equipment Special Tools Special Tools Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Rear wheel cylinder bleeder screw 15 ft.lb Rear wheel cylinder bolts 11 ft.lb Brake line-to-rear wheel cylinder fitting 13 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 6836 Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation 1. Remove the brake shoes and linings. 2. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder. 3. To install, reverse the removal procedure. 4. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Disc brake caliper bleeder screw 15 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding Caliper WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6843 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Disc brake is shown, drum brake is similar. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6844 4. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6845 Brake Bleeding: Service and Repair Brake System Pressure Bleeding Pressure WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Disc brake is shown, drum brake is similar. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6846 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6847 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: This procedure only needs to be carried out if a new 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. NOTE: Disc brake is shown, drum brake is similar. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6848 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Repeat the bleed procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6849 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Master Cylinder Priming-In-Vehicle or Bench WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake component and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. 2. For bench priming, mount the brake master cylinder in a vise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6850 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, loosen the speed control pressure switch. 5. Slowly depress and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the brake pedal. 6. Tighten the speed control pressure switch. 7. Repeat the above three steps until no air bubbles are visible in the expelled fluid. 8. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 9. If necessary, install the brake master cylinder into the vehicle. 10. Remove the short brake tubes and install the master cylinder outlet tubes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6851 11. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 12. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 13. Tighten the outlet tube fitting at the HCU. 14. Repeat the above three steps until no air bubbles are visible in the expelled brake fluid. 15. Repeat the above four steps for the remaining master cylinder outlet tube. 16. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 17. Have an assistant pump and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6852 18. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 19. Tighten the master cylinder bleeder screw. 20. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 21. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Page 6853 Brake Bleeding: Tools and Equipment Special Tools Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper bleeder screw, rear 15 in.lb Caliper bleeder screw, front 15 in.lb Front disc brake caliper anchor plate bolts 72-97 ft.lb Disc brake caliper bolts 21-26 ft.lb Brake caliper bolts 20 ft.lb Caliper flow bolt 23-29 ft.lb Rear wheel disc brake adapter bolts 80 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Caliper Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Use of any other than approved DOT 3 brake fluid will cause damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not clamp the brake hose. The hose can be damaged. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6859 5. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers; connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Check the brake system for correct operation. Caliper Disassembly and Assembly Caliper Disassembly WARNING: Use of any brake fluid other than approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6860 CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25A. ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid. 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6861 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal 1. NOTE: 4x4 is shown, 4x2 is similar. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6862 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6863 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Caliper Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not clamp the brake hose. The hose can be damaged. Disconnect the brake hose. 1 Remove the bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-MlC171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6864 5. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Connect the brake hose and install the caliper flow bolt. Use new copper washers. 3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Verify correct brake operation. Caliper Disassembly and Assembly Caliper Disassembly WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6865 WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear disc brake piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear disc brake piston out to the block of wood. 4 Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6866 1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ cylinder bore ^ piston seal ^ rear disc brake piston ^ dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Rear Disc Brake Adapter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6867 Adapter Removal and Installation 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the bolts and the rear wheel disc brake adapter. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 6868 Brake Caliper: Tools and Equipment Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Dot 4 may be used if Dot 3 is not available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 6872 Brake Fluid: Description and Operation Brake Fluid WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25A. ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6876 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6877 Brake Fluid Level Sensor/Switch: Description and Operation Warning Switch, Brake Fluid Level The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Front brake hose bolt 26 ft.lb Front brake hose bracket 11 ft.lb Rear brake hose to caliper bolt 26 ft.lb Brake hose bracket to rear axle bolt 11 ft.lb Front brake tube 13 ft.lb Rear brake tube fitting 13 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 6881 Brake Hose/Line: Description and Operation Brake Tubes and Hoses CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which can result in brake tube failure. If a section of brake tube is damaged, a new section of the same type, size, shape and length must be installed. When installing hydraulic brake tubing, hoses, or connectors, tighten all connections to specifications. After installation, bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications Brake pressure control valve 13 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Hydraulic control unit (HCU) to bracket bolts 71 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6888 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit The HCU consists of the following components: ^ brake pressure control valve block ^ pump motor New brake pressure control valve block and pump motor are installed as an assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6889 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6890 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the hydraulic control unit (HCU). 4. Remove the HCU. 1 Remove the bolts. 2 Remove the HCU. 5. If necessary, remove the anti-lock brake control module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6891 6. CAUTION: After the electronic hydraulic control unit is installed, it is necessary to bleed the hydraulic brake system. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Brake master cylinder tube fitting, front 11-14 ft.lb Brake master cylinder tube fitting, rear 11-14 ft.lb Master cylinder bleeder screw 70-159 in.lb Brake master cylinder nut 17 ft.lb Master cylinder brake tube nuts 13 ft.lb Master cylinder bleeder screw 10 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6895 Brake Master Cylinder: Description and Operation Brake Master Cylinder The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. The following conditions are considered normal and not indications that the brake master cylinder is in need of repair or replacement: ^ Low brake fluid level detected without signs of leakage. This condition is caused by displacement of brake fluid from the brake master cylinder reservoir into the disc brake calipers/rear disc brake calipers to compensate for normal brake wear. Fill the brake master cylinder reservoir with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ A momentary or slight squirt of brake fluid inside the brake master cylinder reservoir upon application of the brake pedal. ^ A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting flange. This condition results from the lubricating action of the brake master cylinder wiping seal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6896 Brake Master Cylinder: Testing and Inspection Brake Master Cylinder Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to the Symptom Chart at Brakes and Traction Control/Testing and Inspection for abnormal condition diagnosis. Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or installed new. Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6897 Brake Master Cylinder: Adjustments Push Rod Adjustment 1. Remove the brake master cylinder. 2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster. Adjust the power brake booster to brake master cylinder push rod, vacuum applied. 1 Measure the power brake booster to brake master cylinder push rod. 2 If necessary, adjust the screw to the correct length. 3. Install the brake master cylinder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation Master Cylinder Removal and Installation WARNING: Use of any other brake fluid than approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. On cruise control equipped vehicles, disconnect the brake pressure switch. 2. Disconnect the brake fluid level warning switch. 3. Disconnect the two brake lines, and plug the lines and the brake master cylinder ports. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6900 4. Remove the wiring retainer clip from the master cylinder. 5. Remove the nuts and the brake master cylinder. 6. To install, reverse the removal procedure. ^ Bleed the brake master cylinder before installation. ^ Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6901 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Reservoir Removal and Installation WARNING: Use of any other brake fluid than approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycols ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the brake master cylinder fluid level warning switch. 2. Use a suitable suction device to drain the brake master cylinder reservoir. 3. Carefully pry up on the brake master cylinder reservoir to remove. 4. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets. Install the brake master cylinder reservoir. 1 Lubricate the two grommets with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the brake master cylinder. 2 Press the brake master cylinder reservoir into the grommets until it snaps. 3 Connect the brake master cylinder fluid level warning switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6902 4 Fill the brake master cylinder reservoir with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Rear wheel cylinder bleeder screw 15 ft.lb Rear wheel cylinder bolts 11 ft.lb Brake line-to-rear wheel cylinder fitting 13 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 6906 Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation 1. Remove the brake shoes and linings. 2. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder. 3. To install, reverse the removal procedure. 4. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Parking brake cable and conduit clip bolt ........................................................................................................................................................... 11-14 ft lbs. Parking brake cable retainer clip bolt ............................................................................................................................................................. 54-70 inch lbs. Parking brake cable retainer screws ........................................................................... .............................................................................................. 15 ft lbs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front Parking Brake Cable: Service and Repair Cable and Conduit - Front Cable and Conduit-Front Removal 1. Remove the parking brake control. 2. Disconnect the front parking brake cable from the parking brake control. 3. Remove the front parking brake cable and conduit housing. 1 Compress the front parking brake cable and conduit-to-parking brake control clip. 2 Remove the front parking brake cable and conduit housing. Installation 1. Follow the removal procedure in reverse order. ^ Make sure cable is routed through loop on take up spool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6913 Parking Brake Cable: Service and Repair Cable and Conduit - Rear Cable and Conduit-Rear Removal All vehicles 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a 4 mm (5/32-inch) drill bit or equivalent retainer into the parking brake control. 2. Remove the tire and wheel assembly. 3. NOTE: Disconnect the parking brake intermediate cable from the locating hole end of the connector. Disconnect the parking brake intermediate cable from the LH parking brake rear cable and conduit. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6914 4. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and conduit at the parking brake cable equalizer. Vehicles with drum brakes 5. Remove the screws. All vehicles 6. Remove the RH parking brake rear cable and conduit to LH parking brake rear cable and conduit clip. 7. Remove the RH parking brake rear cable and conduit from the parking brake cable bracket. 1 Compress the parking brake cable clip. 2 Remove the RH parking brake rear cable and conduit from the parking brake cable bracket. Vehicles with rear disc brakes Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6915 8. Remove the RH parking brake rear cable and conduit from the rear parking brake cable retainer. All vehicles 9. Remove the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. 10. Remove the parking brake cable retainer clip. 1 Remove the parking brake cable retainer clip bolt. 2 Remove the parking brake cable retainer clip. 11. Unclip the parking brake rear cable and conduit from the brake line clip on top of the rear axle housing. Vehicles with rear disc brakes Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6916 12. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. 13. Unclip the parking brake rear cable and conduit from the parking brake lever. 14. Remove the secondary brake shoe. 15. NOTE: It is not necessary to disconnect the parking brake lever from the brake shoe. Disconnect the cable from the parking brake lever. 16. Compress the retainer and remove the cable and conduit. Installation Vehicles with rear disc brakes Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6917 1. Clip the parking brake rear cable and conduit to the parking brake lever. 2. Connect the parking brake rear cable and conduit to the rear disc brake caliper anchor plate. Vehicles with rear drum brakes 3. Secure the brake cable retainer to the backing plate. 4. Install the secondary brake shoe. All vehicles 5. Clip the parking brake rear cable and conduit to the brake line clip on top of the rear axle housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6918 6. Install the parking brake cable retainer clip. 1 Position the parking brake cable retainer clip. 2 Install the parking brake cable retainer clip bolt. 7. Install the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. Vehicles with rear disc brakes 8. Hook the RH parking brake rear cable and conduit to the rear parking brake cable retainer. All vehicles 9. Connect the RH parking brake rear cable and conduit to the parking brake cable bracket. 1 Install the RH parking brake rear cable and conduit to the parking brake cable bracket. 2 Push the RH parking brake rear cable and conduit into the parking brake cable bracket until the parking brake cable and conduit clip is seated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6919 10. Install the RH parking brake rear cable and conduit to the LH parking brake rear cable and conduit clip. Vehicles with rear drum brakes 11. Install the screws. All vehicles 12. Connect the RH parking brake rear cable and conduit to the LH parking brake rear cable and conduit at the parking brake cable equalizer. 13. Connect the parking brake intermediate cable to the LH parking brake rear cable and conduit. 14. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the front wheel and tire assemblies. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6920 15. Apply tension to the parking brake system. 1 Pull down on the front parking brake cable and conduit. 2 Remove the retainer from the parking brake control. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Parking brake control bolts .................................................................................................................. ............................................................... 13-17 ft lbs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6924 Parking Brake Control: Service and Repair Control Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull down on the parking brake intermediate cable. 2 Insert a 4 mm (5/32-inch) drill bit or equivalent retainer in the parking brake control. 2. Remove the LH front fender apron. 3. Remove the front parking brake cable and conduit from the retainer clip. 1 Remove the front parking brake cable and conduit retainer clip bolt. 2 Remove the front parking brake cable and conduit retainer clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6925 4. NOTE: Disconnect the front parking brake cable and conduit at the locating hole end of the connector. Disconnect the front parking brake cable and conduit from the parking brake intermediate cable. 5. Remove the front parking brake cable and conduit from the bucket. 1 Compress the retainer from the front parking brake cable and conduit from the bracket. 2 Remove the front parking brake cable and conduit from the bracket. 6. Remove the parking brake release mounting bolts. 7. Remove the parking brake control and front parking brake cable and conduit. 1 Disconnect the parking brake signal switch electrical connector. 2 Remove the three parking brake control bolts. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6926 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications Parking Brake Shoe: Specifications Parking brake shoes and lining minimum thickness 0.04 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6930 Parking Brake Shoe: Service and Repair Shoes Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a 4 mm (5/32-inch) drill bit or equivalent retainer. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Remove the rear brake disc. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6931 5. Remove the brake shoe retracting spring. 6. Remove the brake shoe adjusting screw spring. 7. Remove the brake adjuster screw. 8. Remove the rear brake shoe hold-down springs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6932 9. Remove the rear brake shoes and linings along with the inboard brake shoe retracting spring. 10. Inspect the components for excessive wear or damage and install new as required. Installation 1. NOTE: Lubricate the brake shoe contact point before installation of rear shoes using Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-MIC171-A. Install the rear brake shoes and linings along with the inboard brake shoe retracting spring. 2. Install the brake shoe hold-down springs. 3. Install the brake adjuster screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6933 4. Install the brake shoe adjusting screw spring. 5. Install the outboard brake shoe retracting spring. 6. Use Brake Adjusting Gauge to measure the inside diameter of the drum portion of the rear brake disc. 7. Use Brake Adjusting Gauge to set the rear brake shoe and lining diameter to 0.5 mm (0.020 inch) less than the inside diameter of the drum portion of the rear brake disc. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6934 8. Install the rear brake disc. 9. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal to metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 10. Install the wheel and tire assembly. 11. Apply tension to the parking brake cable system. 1 Hold the front parking brake cable and conduit taut. 2 Remove the retainer from the parking brake control. 12. Check operation of the parking brake. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6935 Parking Brake Shoe: Tools and Equipment Special Service Tool(s) Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power brake booster push rod length 0.99-1.01 in Power brake booster nuts 15-20 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6943 Vacuum Brake Booster: Description and Operation Brake Booster The power brake booster: ^ is a dual diaphragm, vacuum assisted power brake booster. ^ is located on the RH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. ^ is divided into separate chambers by the diaphragm. ^ will not operate if vacuum is restricted or if any of the vacuum related power brake components fail. ^ is installed as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Hose and Check Valve The power brake booster check valve: ^ is located on the front of the power brake booster. ^ is positioned between the power brake booster and the power brake booster hose. ^ closes when the engine is turned off. ^ in the closed position, traps engine vacuum in the power brake booster. ^ retains vacuum to provide several power assisted brake applications with the engine off. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6944 Vacuum Brake Booster: Testing and Inspection Brake Booster 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Continue the test with the following steps. 4. Remove the vacuum booster hose from check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster, connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2 and 3 above. 5. Check and if no downward movement of the brake pedal is felt, install a new power brake booster. 6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lbs.) of force. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), install a new check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6945 Vacuum Brake Booster: Service and Repair Brake Booster Removal 1. Remove the brake master cylinder. 2. Disconnect the power broke booster hose. 1 Compress the clamp. 2 Disconnect the power brake booster hose. 3. Disconnect the brake pedal to power brake booster push rod. 1 Remove the self-locking pin. 2 Remove the stoplight switch and the brake booster push rod from the brake pedal pin. 3 Remove the brake booster push rod bushing. 4. Remove the bulkhead sound insulator. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6946 5. NOTE: Support the power brake booster. Remove the power brake booster. 1 Remove the nuts. 2 Remove the power brake booster. Installation 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation Hose and Check Valve The power brake booster check valve: ^ is located on the front of the power brake booster. ^ is positioned between the power brake booster and the power brake booster hose. ^ closes when the engine is turned off. ^ in the closed position, traps engine vacuum in the power brake booster. ^ retains vacuum to provide several power assisted brake applications with the engine off. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 6950 Vacuum Brake Booster Check Valve: Testing and Inspection Check Valve The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve: ^ Start and run the engine for at least 10 seconds. ^ Operate the brake pedal to check for power assist. ^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the power brake booster check valve from the power brake booster. ^ There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake Operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON DTCB2607 May Be Set Article No. 01-6-1 04/02/01 ^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY FORD: 2001 EXPLORER ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607 may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp may remain on or may illuminate intermittently. This may be due to the ABS module remaining active when the engine is cranked and both blower motors are on. ACTION Replace the ABS module with an updated module if existing module is the original design, and check for proper circuit grounding. Refer to the following Service Procedure for details. SERVICE PROCEDURE It the ABS lamp is on intermittently: 1. Replace the ABS module. a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Test drive vehicle to verify repair. If the ABS lamp is on continuously: 1. Replace the ABS module. a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 3. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6960 b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 3. Verify if the vehicle is a 4X4 or 4X2. ^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded. ^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary. 4. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 5. b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 301000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON DTCB2607 May Be Set Article No. 01-6-1 04/02/01 ^ BRAKES - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ ELECTRICAL - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY ^ LAMP - ANTI-LOCK BRAKE LAMP ILLUMINATED - WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) B2607 STORED IN MEMORY - SPORT AND SPORT TRAC VEHICLES ONLY FORD: 2001 EXPLORER ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B2607 may or may not be set in the ABS module on some Sport and Sport Trac vehicles. The ABS lamp may remain on or may illuminate intermittently. This may be due to the ABS module remaining active when the engine is cranked and both blower motors are on. ACTION Replace the ABS module with an updated module if existing module is the original design, and check for proper circuit grounding. Refer to the following Service Procedure for details. SERVICE PROCEDURE It the ABS lamp is on intermittently: 1. Replace the ABS module. a. 4X4 vehicle: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicle: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Test drive vehicle to verify repair. If the ABS lamp is on continuously: 1. Replace the ABS module. a. 4X4 vehicles: Replace the module with part number 1L5Z-2B373-AB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. b. 4X2 vehicles: Replace the module with part number 1L5Z-2B373-BB. Refer to the 2001 Explorer Workshop Manual, Section 206-09 for installation instructions. 2. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 3. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-6-1 > Apr > 01 > Brakes - ABS Lamp ON DTCB2607 May Be Set > Page 6966 b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 3. Verify if the vehicle is a 4X4 or 4X2. ^ For 4X4 model, Pin 14 (Circuit 571) of the ABS module must be grounded. ^ For 4X2 model, Pin 14 (Circuit 571) should not be grounded. Repair as necessary. 4. Turn the key to the Run position for 5 seconds. a. If ABS lamp remains on after bulb check, continue with Step 5. b. If the ABS lamp goes out after bulb check, drive the vehicle to verify repair. 5. Refer to the Workshop Manual, Section 206-09 for additional diagnostics for DTC B2607. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 301000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Valve: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6972 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6973 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6974 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6975 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6976 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6977 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6983 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6984 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6985 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6986 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6987 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 6988 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6989 Electronic Brake Control Module: Specifications Control module bolts 13 in.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6990 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6991 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6992 Electronic Brake Control Module: Description and Operation Anti-Lock Brake Control Module NOTE: The new anti-lock brake control module must be reconfigured upon installation. The anti-lock brake control module is mounted to the HCU. It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and the necessary circuitry for their operation. The anti-lock brake control module monitors system operation during normal driving as well as during anti-lock braking. Anti-lock brake module operation is as follows: ^ Under normal driving conditions, the microprocessor produces short test pulses to the solenoid valves that check the electrical system without any mechanical reaction. ^ Impending wheel lock conditions trigger signals from the anti-lock brake control module that open and close the appropriate solenoid valves. This results in moderate pulsations in the brake pedal. During normal braking, the brake pedal feel will be identical to a standard brake system. Most faults that occur in the anti-lock brake system will be stored as a diagnostic trouble code (DTC) in the keep-alive memory of the anti-lock brake control module. The DTCs can be retrieved by following the on-board diagnostic procedures. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6993 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6994 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the electrical connectors. 3. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the anti-lock brake control module. 4. CAUTION: Once the new module is installed, the module configuration information may have to be entered. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6999 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7000 Brake Fluid Level Sensor/Switch: Description and Operation Warning Switch, Brake Fluid Level The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations > Page 7004 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Front Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 8.5 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Front > Page 7012 Wheel Speed Sensor: Specifications Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 7015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 7018 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 7019 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 7020 Wheel Speed Sensor: Description and Operation Anti-Lock Brake Sensor NOTE: Any time an anti-lock brake sensor is removed, thoroughly clean the mounting surfaces. On front anti-lock brake sensors, apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. The anti-lock brake system uses three variable-reluctance sensors to determine vehicle speed. The anti-lock brake sensors operate on magnetic induction principle. As the teeth on the anti-lock brake sensor indicator rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and sent to the anti-lock brake control module through a twisted cable and shielded wiring harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control Wheel Speed Sensor: Service and Repair Rear Antilock Control Sensor-Rear Removal and Installation 1. Raise and support vehicle. 2. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. 3. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 7023 Wheel Speed Sensor: Service and Repair Sensor, Front Sensor-Front 4x2 Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front anti-lock brake sensor. 4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Antilock Control > Page 7024 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor-Rear Removal and Installation NOTE: The rear anti-lock brake sensor indicator is attached to the differential case. For additional information, refer to Transmission and Drivetrain; Differential. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7035 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7036 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 7040 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7045 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7046 Starter Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7047 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - Battery Eye Function/Charging/Service Battery: Technical Service Bulletins Battery - Battery Eye Function/Charging/Service TSB 07-5-8 03/19/07 BATTERY SERVICE - OPERATION OF BATTERY EYE - CHARGING SERVICE TIPS FORD: 1999-2003 Escort 2000-2006 Taurus 2000-2007 Crown Victoria, Focus, Mustang 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 2000-2003 Windstar 2000-2004 Explorer Sport 2000-2006 Excursion 2000-2007 E-Series, Expedition, Explorer, F-150, F-250 Light Duty, F-53 Motorhome Chassis, F-Super Duty, Ranger 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004-2006 Freestar 2005-2007 Escape Hybrid 2007 Edge 2000-2007 F-650, F-750 2006 Low Cab Forward LINCOLN: 1998-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2002 Blackwood 2003-2005 Aviator 2006-2007 Mark LT, Mark LT 2007 MKX MERCURY: 1999-2002 Cougar 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2002 Villager 2000-2007 Mountaineer 2004-2006 Monterey 2004-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 06-4-2 to update the vehicle model years. ISSUE This TSB describes the operation and function of the Battery Eye and correct Battery Recharging procedures. ACTION Refer to the following Service Tips to avoid misdiagnosis of a battery using the Battery Eye, and to determine the best way to charge a battery that may be discharged. SERVICE TIPS Battery Eye Operation / Function Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - Battery Eye Function/Charging/Service > Page 7052 The purpose of the battery eye is to indicate the state of charge of the battery in the assembly plant and while on the dealership lot. The battery eye can also indicate the state-of-charge when the vehicle is delivered to the dealership and during the pre-delivery inspection process. The battery eye is made up of a viewing plate, two balls and a small passage. The balls indicate the specific gravity of the electrolyte by floating higher or lower in the passageway. It is important to note that the battery eye checks the specific gravity on only one battery cell. ^ RED usually indicates that the battery state-of-charge is at 40 percent or less ^ YELLOW indicates that the battery state-of-charge is between 40 and 57 percent ^ GREEN indicates that the battery state-of-charge is above 57 percent ^ NO COLOR/BLACK sometimes no color can be seen at all and the eye appears black. This could happen after the battery has been in service for several years and some of the plate material has coated the balls ^ CLEAR could happen if the battery case becomes damaged and the electrolyte has fallen below the plates The battery eye is a state-of-charge indicator, but should not be used to condemn a battery after the vehicle has been placed in service. After delivery, many things could happen to cause the battery eye to lead to misdiagnosis of the battery's actual state-of-charge. After the vehicle has been in service, the battery eye does not always accurately reflect the battery state-of-charge. The GR-1 190 Battery Tester/Charge or Micro 490 Digital Battery Analyzer should be used to determine battery condition. Do not replace a battery based solely on the indication given by the battery eye. The battery eye color simply indicates the battery state-of-charge, not its condition. If the eye indicates the battery may be discharged, Use GR-1 190 Battery Tester/Charger to determine the battery condition or recharge the battery before testing using the Micro 490. A red or yellow indicator usually means that the battery is discharged, not defective. Therefore, a battery with a red or yellow eye should not automatically be replaced. The indicator could remain red after recharge because the balls are stuck in the passageway. When new vehicles are delivered to the dealership, be sure to check the state-of-charge indicator within 72 hours. If the battery eye is red, charge the battery until it is fully charged. Refer to the following Battery Charging Procedure. Batteries discharge while the vehicle is on the lot due to normal parasitic key-off loads. Also, vehicles in inventory are generally driven short distances with heavy electrical loads. Over a period of time (30 days or more), vehicles still in inventory will have shallow to deeply discharged batteries. The vehicle's charging system is designed to supply the vehicle's electrical power needs and maintain the battery near full charge during normal vehicle use. The charging system is not capable of bringing a deeply discharged battery back near full charge in a short amount of time such as allowing the vehicle to idle for 15 minutes to "recharge the battery". Discharged batteries should be charged using an external charger. Refer to the following Battery Charging Procedure. NOTE THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS), EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY MIXED. Battery Charging Procedure Dealers with GR-1 190, use the Diagnostic Fast Charge Mode on GR-1 190 for this procedure and for dealers without a GR-1 190 the following procedure applies: The Micro 490 Digital Battery Analyzer (Rotunda Part Number 162-00004) is extremely accurate if used properly and can distinguish the difference between good, defective, worn out, or discharged-only batteries. This TSB provides proper battery charging procedures for batteries that are identified as "discharged-only". Discharged-only batteries can be recharged using the procedures in this TSB without reducing battery life or charge capacity. NOTE BATTERY CHARGERS HAVE IMPROVED GREATLY WITH THE ADDITION OF THE NEW GENERATION OF "PULSE CHARGERS". THESE NEW CHARGERS PULSE CURRENT INTO THE BATTERY THAT BREAKS DOWN THE SULFATION LAYER ON THE BATTERY PLATES AND GENERALLY REDUCE CHARGING TIMES TO LESS THAN 1 HOUR. ^ DEEPLY DISCHARGED - A battery that is drained over a prolonged period of time such as an unsold vehicle, to the point it is dead ^ SHALLOW DISCHARGE - A battery that is drained by leaving an accessory on for several hours or a few days, and has a very low charge Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - Battery Eye Function/Charging/Service > Page 7053 The chart information summarizes two (2) recommended methods of charging. NOTE COLD BATTERIES WILL NOT READILY ACCEPT A CHARGE. THEREFORE, BATTERIES SHOULD BE ALLOWED TO WARM TO APPROXIMATELY 41° F (5° C) BEFORE CHARGING. THIS MAY REQUIRE 4 TO 8 HOURS AT ROOM TEMPERATURE. A battery which has been completely discharged and left in that condition for a prolonged time (such as an unsold vehicle) may be slow to accept a charge initially, and in some cases may not accept a charge at the normal charger setting. When batteries are in this condition, charging can be started by use of the "dead battery" feature on chargers so equipped. Follow charger manufacturer's instructions for use of dead battery switch. If switch is the spring-loaded type, it may need to be held in the ON position for up to 3 minutes. NOTE THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS), EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY MIXED. For additional information, refer to the PTS Website, web based Technician training "Fix It Right The First Time" course "Battery Testing and Charging 34G02W0" (website). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070508 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 10655 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications Battery: Electrical Specifications Battery/Alternator Specifications Parasitic Draw (Current Drain) Less Than 0.05 amps For testing procedures, please refer to Battery Drain Test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications > Page 7056 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Page 7057 Battery: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Technician Safety Information Battery: Technician Safety Information WARNING: ^ DO NOT ATTEMPT THIS LEST ON A LEAD-ACID BATTERY THAT HAS RECENTLY BEEN RECHARGED. EXPLOSIVE GASES CAN CAUSE PERSONAL INJURY. ^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR INSTALLING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE REPAIRING, INSTALLING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN PERSONAL INJURY. REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ KEEP OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Technician Safety Information > Page 7060 Battery: Vehicle Damage Warnings CAUTION: To prevent damage to the meter, do not crank the engine or operate accessories that draw more than 10A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Page 7061 Battery: Description and Operation Environmental Protection Vehicles are equipped with a 12 volt maintenance-free battery. The battery and cable system consists of the following components: ^ battery ^ battery cable assembly ^ battery tray Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling facility for disposal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Battery: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for a concern is found, correct the cause before proceeding to the next step. 4. If the fault is not visually evident, proceed to the pinpoint test. See: Pinpoint Tests Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7064 A1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7065 Battery: Component Tests and General Diagnostics Battery Drain Test NOTE: No production vehicle should have more than a 50 mA (0.050 amp) continuous draw. Check for current drains on the battery in excess of 50 milliampere (0.050 amp) with all the electrical accessories off and the vehicle at rest. Current drains can be tested with the following procedure: WARNING: DO NOT ATTEMPT THIS LEST ON A LEAD-ACID BATTERY THAT HAS RECENTLY BEEN RECHARGED. EXPLOSIVE GASES CAN CAUSE PERSONAL INJURY. CAUTION: To prevent damage to the meter, do not crank the engine or operate accessories that draw more than 10A. NOTE: ^ Many modules draw 10 mA (0.010 amp) or more continuously. ^ Use an in-line ammeter between the battery positive or negative post and its respective cable. ^ Typically, a drain of approximately one amp can be attributed to an engine compartment lamp, glove compartment lamp, or luggage compartment lamp staying on continually. Other component failures or wiring shorts may be located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is found, the meter reading will fall to an acceptable level. If the drain is still not located after checking all the fuses, it may be due to the generator. ^ To accurately test the drain on a battery, an in-line digital ammeter must be used. Use of a test lamp or voltmeter is not an accurate method due to the number of electronic modules. 1. Make sure the junction box/fuse panels are accessible without turning on interior and underhood lights. 2. Drive the vehicle at least five minutes and over 48 km/h (30 mph) to turn on and exercise the vehicle systems. 3. Allow the vehicle to sit with the key off for atleast 40 minutes to allow modules to time out/power down. 4. Connect a fused jumper wire between the negative battery cable and the negative battery post to prevent modules from resetting and to catch capacitive drains. 5. Disconnect the negative battery cable from the post without breaking the connection of the jumper wire. 6. Connect the tester between the negative battery cable and the post. The meter must be capable of reading milliampere and should have a 10 amp capability. NOTE: It is very important that continuity is not broken between the battery and the negative battery cable when connecting the meter. If this happens, the entire procedure must be repeated. 7. Remove the jumper wire. NOTE: If the meter settings need to be switched or the test leads need to be moved to another jack, the jumper wire must be reinstalled to avoid breaking continuity. NOTE: ^ Amperage draw will vary from vehicle to vehicle depending on the equipment package. Compare to a comparable vehicle for reference. ^ No production vehicle should have more than a 50 mA (0.050 amp) draw. 8. If the draw is found to be excessive, pull fuses from the battery/central junction box one at a time and note the current drop. Do not reinstall the fuses until you are finished testing. 9. Check the wiring schematic in the wiring diagram for any circuits that run from the battery without passing through the battery/central junction box . Disconnect these circuits if the draw is still excessive. Battery Load Test 1. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam. 2. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. ^ If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests. See: Charging System/Testing and Inspection/Component Tests and General Diagnostics/Generator Testing ^ If the voltage increases as specified, the charging system is operating normally. Electronic Drains That Shut Off When The Battery Cable Is Disconnected 1. Repeat the steps of the battery drain testing. 2. Make sure all doors are closed and accessories are off. Without starting the engine, turn the ignition switch to RUN for a moment and then OFF. Wait a few minutes for the illuminated entry lamps to turn off if equipped. 3. Connect the ammeter and read the amperage draw. Test Conclusion Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7066 The current reading (current drain) should be less than 50 mA (0.05 amp). If the current drain exceeds 50 mA (0.05 amp) after a few minutes, and if this drain did not show in previous tests, the drain is most likely caused by an inoperative electronic component. As in previous tests, remove the fuses from the battery/central junction box one at a time to locate the problem circuit. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7067 Battery Analyzer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Removal and Installation Battery: Service and Repair Removal and Installation Battery REMOVAL 1. Disconnect the battery cables. 2. Remove the battery heat shield. 3. Remove the hold-down bolt and the bracket. 4. Remove the battery. WARNING: WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. INSTALLATION 1. To install, reverse the removal procedure. Battery Tray REMOVAL 1. Remove the battery. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Removal and Installation > Page 7070 2. Remove the battery ground cable to battery tray pin-type retainer. 3. Remove the cable to battery tray pin-type retainer. 4. Remove the bolt and the nut. 5. Remove the battery tray. 1 Remove the bolt. 2 Remove the battery tray. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Removal and Installation > Page 7071 Battery: Service and Repair Battery Disconnect WARNING: ^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR INSTALLING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE REPAIRING, INSTALLING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN PERSONAL INJURY. REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ KEEP OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy. 2. Disconnect the positive battery cable. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Page 7072 Battery Analyzer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Generator Output (Minimum) 58 A at 2,000 rpm Generator Output 13.0 - 15.0 V at 2,000 rpm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 7078 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7094 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7095 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7096 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7097 Alternator: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7098 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7099 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7100 Alternator: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 7101 Alternator: Description and Operation The generator system consists of: ^ generator ^ battery ^ wiring harness Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Generator Testing Alternator: Testing and Inspection Generator Testing CAUTION: ^ To prevent damage to the generator, do not make the jumper wire connections except as directed. ^ Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with key on or off. A short circuit will result and burn out the diodes. NOTE: ^ Battery posts and cable clamps must be clean and tight for accurate meter indications. ^ Refer to the battery tester manual for complete directions for testing the charging system. 1. Turn off all lamps and electrical components. 2. Place the transmission range selector lever in NEUTRAL and apply the parking brake. 3. Carry out the Load Test and No-Load Test according to the following component tests: Generator On-Vehicle Tests-Load Test 1. Switch the battery tester to the ammeter function. 2. Connect the positive and negative leads of the battery tester to the corresponding battery terminals. 3. Connect the current probe to the generator B+ output terminal, circuit 38 (BK/OG). 4. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam. 5. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. ^ If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests. ^ If the voltage increases as specified, the charging system is operating normally. 6. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the generator. Generator output should be at least 58 amps. Generator-On Vehicle Test-No-Load Test 1. Switch the battery tester to the voltmeter function. 2. Connect the voltmeter positive lead to the generator B+ output terminal, circuit 38 (BK/OG) and the negative lead to ground. 3. Turn all electrical accessories off. 4. With the engine running at 2,000 rpm, check the generator output voltage. The voltage should be between 13.0 and 15.0 volts. If not, refer to the Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Generator Testing > Page 7104 Alternator: Testing and Inspection Other Diagnosis and Testing For further information regarding the diagnosis of this component, please refer to Charging System; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Page 7105 Alternator: Service and Repair REMOVAL 1. Disconnect the battery. 2. Remove the air cleaner outlet tube. 3. Remove the drive belt. 4. Disconnect the wiring harness to voltage regulator electrical connector. 5. Remove the B+ terminal cover. 6. Remove the B+ terminal electrical connector. 1 Remove the B+ terminal nut. 2 Disconnect the B+ terminal electrical connector. 7. Remove the wiring harness-to-generator pin-type retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Page 7106 8. Remove the generator. 1 Remove the stud bolts and nut. 2 Remove the generator. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7116 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7117 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 7121 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection Starter Drive/Bendix: Testing and Inspection Starter Drive and Flywheel Ring Gear Inspection 1. Remove the starter motor. Refer to Starter Motor. 2. Check the wear patterns on the starter drive gear and the flywheel ring gear. If the wear pattern is abnormal, install a new starter motor, refer to Starter Motor. 3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are scored or damaged, install a new starter motor, refer to Starter Motor. If necessary, install a new flywheel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7129 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7130 Starter Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7131 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7150 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7151 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7152 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7153 Auxiliary Power Outlet: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7154 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7155 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7156 Auxiliary Power Outlet: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7157 Diagram 501-12-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 7158 Auxiliary Power Outlet: Service and Repair PANEL - POWER POINT Removal and Installation 1. Disconnect the battery ground cable 2. Remove the screws and position the power point receptacle and panel aside. 3. Disconnect the power point receptacle electrical connector. 4. Remove the power point receptacle from the panel. 1. Remove the screws. 2. Remove the power point receptacle. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7167 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7168 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7169 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7170 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7171 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7172 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7173 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7174 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7180 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7181 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7182 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7183 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7184 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7185 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7186 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7187 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Page 7188 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7193 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7194 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7195 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7196 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7197 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7198 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7199 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7200 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7201 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7202 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7203 Fuse: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7204 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7205 Fuse: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7206 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7207 Fuse: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7208 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7211 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7212 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7220 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7221 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7222 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7223 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7224 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 Fuse: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7232 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7233 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7234 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7235 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7236 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7237 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7238 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7239 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7240 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7241 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7242 Fuse: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7243 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7244 Fuse: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7245 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7246 Fuse: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7247 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7252 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7253 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7254 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7255 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7256 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7257 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7258 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7259 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7260 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7261 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7262 Fuse Block: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7263 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7264 Fuse Block: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7265 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7266 Fuse Block: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7267 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Fuse Block: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7292 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7293 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7294 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7295 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7296 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7297 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7298 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7299 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7300 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7301 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7302 Fuse Block: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7303 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7304 Fuse Block: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7305 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7306 Fuse Block: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7307 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7311 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7315 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7320 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7321 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7322 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7323 Multiple Junction Connector: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7324 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7325 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7326 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7327 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7328 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7329 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7330 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7331 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7332 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7333 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7334 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7335 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7336 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7337 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7342 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7346 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7351 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7352 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7353 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7354 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7355 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7356 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7357 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7358 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7359 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7360 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7361 Relay Box: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7362 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7363 Relay Box: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7364 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7365 Relay Box: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7366 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7369 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7370 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7371 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7372 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7373 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7374 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7375 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7376 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7377 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7378 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7379 Relay Box: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7380 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7381 Relay Box: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7382 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7383 Relay Box: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7384 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7389 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7390 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7391 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7392 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7393 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7394 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7395 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7396 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7397 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7398 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7399 Relay Box: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7400 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7401 Relay Box: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7402 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7403 Relay Box: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7404 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7407 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7408 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7409 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7410 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7411 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7412 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7413 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7414 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7415 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7416 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7417 Relay Box: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7418 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7419 Relay Box: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7420 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7421 Relay Box: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7422 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7427 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7428 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7429 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7430 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7431 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7432 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7433 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7434 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7435 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7441 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7442 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7443 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7444 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7445 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 Auxiliary Power Outlet: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 Auxiliary Power Outlet: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 Diagram 501-12-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 7462 Auxiliary Power Outlet: Service and Repair PANEL - POWER POINT Removal and Installation 1. Disconnect the battery ground cable 2. Remove the screws and position the power point receptacle and panel aside. 3. Disconnect the power point receptacle electrical connector. 4. Remove the power point receptacle from the panel. 1. Remove the screws. 2. Remove the power point receptacle. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7471 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7472 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7473 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7474 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7475 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7476 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7477 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7478 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7484 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7485 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7486 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7487 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7488 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7489 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7490 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7491 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Page 7492 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7497 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7498 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7499 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7500 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7501 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7502 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7503 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7504 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7505 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7506 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7507 Fuse: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7508 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7509 Fuse: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7510 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7511 Fuse: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7512 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 Fuse: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7532 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7533 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7536 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7537 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7538 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7539 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7540 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7541 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7542 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7543 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7544 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7545 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7546 Fuse: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7547 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7548 Fuse: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7549 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7550 Fuse: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7551 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7556 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7557 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7558 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7559 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7560 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7561 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7562 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7563 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7564 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7565 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7566 Fuse Block: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7567 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7568 Fuse Block: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7569 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7570 Fuse Block: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7571 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7574 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7575 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7576 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7577 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7578 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7579 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7580 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7581 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7582 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7583 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7584 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7585 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7586 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7587 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7588 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7589 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7590 Fuse Block: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7596 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7597 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7598 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7599 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7600 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7601 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7602 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7603 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7604 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7605 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7606 Fuse Block: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7607 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7608 Fuse Block: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7609 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7610 Fuse Block: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7611 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7615 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7619 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7624 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7625 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7626 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7627 Multiple Junction Connector: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7628 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7629 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7630 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7631 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7632 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7633 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7634 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7635 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7636 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7637 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7638 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7639 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7640 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 7641 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7646 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7650 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7655 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7656 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7657 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7658 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7659 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7660 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7661 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7662 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7663 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7664 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7665 Relay Box: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7666 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7667 Relay Box: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7668 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7669 Relay Box: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7670 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7673 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7674 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7675 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7676 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7677 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7678 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7679 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7680 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7681 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7682 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7683 Relay Box: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7684 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7685 Relay Box: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7686 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7687 Relay Box: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7688 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7693 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7694 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7695 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7696 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7697 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7698 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7699 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7700 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7701 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7702 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7703 Relay Box: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7704 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7705 Relay Box: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7706 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7707 Relay Box: Locations Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7708 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box (CJB) - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7711 Central Junction Box (CJB) - Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7712 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7713 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7714 Fuse 17 - 36 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7715 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Sport, Before June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7716 Sport Trac, Before June 16 Sport, As Of June 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7717 Sport Trac, As Of June 16 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7718 Fuse 1 - 16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7719 Fuse 17 - 46A Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7720 Fuse 46B - 56B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7721 Relay Box: Application and ID Auxiliary Relay Box 3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7722 Vehicle Rear End, LH Side - Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7723 Relay Box: Application and ID Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7724 Engine Compartment, RH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7725 Relay Box: Application and ID Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7726 Behind Dash Panel, LH Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7731 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7732 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7733 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7734 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7735 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7736 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7737 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7738 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7739 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision TSB 04-24-19 12/13/04 REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer Sport Trac ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT NOTE THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT. 1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1). 2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision > Page 7745 3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. 4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward. 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 3084 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7746 Alignment: Specifications Alignment Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7747 General Specifications Related Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7748 Alignment: Description and Operation WHEEL ALIGNMENT ANGLES Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie-rod. Negative and Positive Camber Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Positive Toe (Toe In) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7749 Negative Toe (Toe Out) Toe The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7750 Ride Height Wheel Track Wheel Track Dogtracking Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7751 Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a readability problem, it is important to understand the difference between wander and poor groove feel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment 1. Remove the nuts and alignment plates. 2. Install the cams and the nuts. 3. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase the LF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7754 4. To decrease the LF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. 5. Tighten the nuts. 6. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase RF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 7. To decrease the RF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7755 8. Increase the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts forward. 9. Decrease the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts rearward. 10. Tighten the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7756 Alignment: Service and Repair Ride Height Ride Height 1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to normalize the vehicle static ride height. 3. Measure the distance between the center line of the front suspension lower arm bushing bolt and the lift. Record the measurement. 4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the measurement. ^ Take the measurement from the midpoint of the surface shown. 5. Determine ride height. ^ Subtract measurement 1 from measurement 2. This is the ride height. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7757 6. NOTE: The torsion bar adjusting bolt is coated with adhesive that wears off after disassembly. If the torsion bar system is ever disassembled or the torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when re-assembling. Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting bolt. ^ Tighten the torsion bar adjusting bolt to increase the torque or raise the height. ^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7758 Alignment: Service and Repair Toe Adjustment Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the manufacturer's instructions. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7759 6. Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Front Wheel Spindle Tie-Rod Ball Socket 89 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 7764 Front Steering Knuckle: Service and Repair Special Tool(s) Special Tool(s) Removal 1. Remove the brake disc and hub. 2. Remove the front brake anti-lock sensor. 1 Remove the anti-lock sensor electrical wire from the clamp. 2 Remove the bolt and position the sensor aside. 3. Remove the tie-rod end castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 7765 4. Use the Pitman Arm Puller to separate the tie-rod end from the front wheel spindle. 5. Use a suitable jack stand to support the front suspension lower arm. 6. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it from tilting before removing the pinch bolt and nut. Remove the pinch bolt and nut from the front wheel spindle. 7. Remove the lower ball joint castellated nut. 1 Remove the lower ball joint cotter pin. 2 Remove the lower ball joint castellated nut. 8. Use the Pitman Arm Puller to remove the front wheel spindle. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 7766 1. NOTE: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so can cause damage to the wheel and tire assembly. Install the lower ball joint castellated nut. 1 Position the front wheel spindle to the lower ball joint. 2 Install the lower ball joint castellated nut. 3 Install a new cotter pin. 2. Install the pinch bolt and nut. 1 Position the front wheel spindle. 2 Install the pinch bolt and nut. 3. Remove the jack from under the front suspension lower arm. 4. CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so can cause damage to the wheel and tire assembly. Connect the tie-rod end to the front wheel spindle. 1 Position the tie-rod end. 2 Install the tie-rod end castellated nut. 3 Install a new cotter pin. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 7767 5. Install the front brake anti-lock sensor and position the anti-lock sensor electrical wire in the clamp. 6. Install the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Purging Special Tools Special Tool(s) CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure can result. The condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. 1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The power steering purge procedure must be performed prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. Remove the reservoir cap. Check the fluid. ^ Use MERCON Multi-Purpose(ATF) Transmission Fluid XT-2-QDX or MERCON equivalent. 2. Tightly insert the stopper of the vacuum pump into the reservoir. 3. Start the vehicle. 4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at idle. 5. Release the vacuum and remove the vacuum pump. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7772 6. CAUTION: Do not overfill the power steering pump reservoir (3E764). Fill the reservoir. ^ Use MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or MERCON equivalent. 7. Reinstall the vacuum pump. Apply and maintain maximum vacuum. 8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump can occur. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes. 9. Stop the engine, release the vacuum, and remove the vacuum pump. 10. Install the reservoir cap. 11. Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7777 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 7778 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Fluid Cooler: Customer Interest Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7787 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7788 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7789 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7790 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Fluid Cooler: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7795 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7796 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7797 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7798 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7799 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7800 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Fluid Cooler: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7806 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7807 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7808 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7809 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Fluid Cooler: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7814 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7815 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7816 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7817 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7818 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7819 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Page 7820 Power Steering Fluid Cooler: Specifications Power steering fluid cooler nuts 59 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Page 7821 Power Steering Fluid Cooler: Service and Repair Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the power steering return hose at the power steering fluid cooler. ^ Drain the fluid into a suitable container. 3. Remove the power steering fluid cooler to crossmember nuts. 4. Disconnect the power steering return line hose. Remove the power steering fluid cooler. 5. To install, reverse the removal procedure. ^ Fill, purge and leak check the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Steering line to gear clamp plate nut 18 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 7825 Power Steering Line/Hose: Service and Repair Hose Special Tools Special Tool(s) Removal and Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 7826 1. Refer to the System View illustration for the hose routing and retention points. 2. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 3. Fill, purge and leak check the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Pressure Control Valve: Customer Interest Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7835 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7836 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7837 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7838 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Pressure Control Valve: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7843 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7844 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7845 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7846 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7847 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7848 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Pressure Control Valve: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7854 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7855 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7856 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7857 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Pressure Control Valve: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7862 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7863 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7864 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7865 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7866 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7867 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns Power Steering Pump: Customer Interest Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7876 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7877 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7878 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7879 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped Power Steering Pump: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7884 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7885 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7886 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7887 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7888 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7889 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Pump: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7895 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7896 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7897 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7898 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Pump: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7903 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7904 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7905 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7906 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7907 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7908 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Power Steering Pump Pulley Power Steering Pump: Specifications Power steering pump pulley bolts 18 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Power Steering Pump Pulley > Page 7911 Power Steering Pump: Specifications Type C111 Flow rate 2.2-2.6 gal/min @ 74 degrees-80 degrees C (165 degrees-175 degrees F) and engine speed set at 1500 rpm Maximum Pressure 150 psi @ 74 degrees-80 degrees C ( 165 degrees- 175 degrees F) and engine speed set at 1500 rpm Minium Flow rate 1.15 gal/min @ 74 degrees-80 degrees C (165 degrees-175 degrees F) power steering analyzer set at 5,102kpa (750 psi) and engine speed set at idle Relief pressure 1300-1480 psi Power steering pressure hose to power steering pump 48 ft.lb Power steering pump bolts 18 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7912 Power Steering Pump: Application and ID Power Steering Pump Power Steering Pump Pump Identification CAUTION: Always use the ID code when ordering service parts. The pump identification code is located on a tag attached to the power steering pump. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Special Tools Special Tool(s) Removal 1. Remove the engine cooling fan. 2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt. 4. Remove the power steering pump pulley. 1 Remove the bolts. 2 Remove the power steering pump pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7915 5. Disconnect the power steering return line hose at the power steering fluid reservoir. ^ Allow the system to drain. 6. Disconnect the power steering pressure hose from the power steering pump. 7. Disconnect the power steering fluid reservoir outlet hose from the power steering pump. 1 Compress and move the power steering fluid reservoir outlet hose clamp. 2 Disconnect the power steering fluid reservoir outlet hose from the power steering pump. 8. Remove the power steering pump. 1 Remove the bolts. 2 Remove the power steering pump. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7916 1. Install the power steering pump. 1 Position the power steering pump. 2 Install the bolts. 2. Connect the power steering fluid reservoir outlet hose to the power steering pump. 1 Connect the power steering fluid reservoir outlet hose to the power steering pump. 2 Compress and move the power steering fluid reservoir outlet hose clamp into place. 3. Using the special tool, install a new seal on the power steering pressure hose. 4. Connect the power steering pressure hose to the power steering pump. 5. Connect the power steering return line hose to the power steering fluid reservoir. 6. Install the power steering pump pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7917 1 Position the power steering pump pulley. 2 Install the bolts. 7. Install the drive belt. 8. Tighten the power steering pump pulley bolts. 9. Install the engine cooling fan. 10. Fill, purge and leak check the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7918 Power Steering Pump: Service and Repair Power Steering Pump Pulley Removal and Installation 1. Remove the engine cooling fan. 2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt. 4. Remove the power steering pump pulley. 1 Remove the bolts. 2 Remove the power steering pump pulley. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped Power Steering Valve: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7927 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7928 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7929 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7930 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7931 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7932 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Valve: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7938 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7939 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7940 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7941 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7942 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7943 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor connector. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side floor connector. 11. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7949 STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector beneath the front seat. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag electrical connector beneath the front seat. 11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat. 12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side air bag electrical connector beneath the front seat. 13. Reconnect the battery ground cable. Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7950 NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7951 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7952 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7953 Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7954 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7955 Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7956 14. Install the two screws. 15. Close the glove compartment door. 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7957 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Procedures For Repair Operations Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7958 accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7959 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7960 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7961 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7962 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic tool from the driver seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7963 8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. Prove out the system. Seats Not Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the front passenger seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the driver seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver seat. 10. Reconnect the battery ground cable. 11. Prove out the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7964 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7965 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Functional Lock Cylinder Steering Column Lock: Service and Repair Functional Lock Cylinder Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Functional Lock Cylinder > Page 7970 Steering Column Lock: Service and Repair Non-Functional Lock Cylinder Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package (F85Z-1 1582-AA). The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Functional Lock Cylinder > Page 7971 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Steering gear turns (stop-to-stop) 4.0 : 1 Steering gear to crossmember stud bolts and nuts (E coated frame) 111 ft.lb Steering gear to crossmember stud bolts and nuts (wax-coated frame) 148 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7975 Steering Gear: Diagrams Steering Gear Mounting Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7976 Steering Gear Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7977 Steering Gear: Application and ID Steering Gear Identification Explorer Sport Explorer Sport Trac CAUTION: Always use the ID code when ordering service parts. The steering gear identification code is located on a tag attached to the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7978 Steering Gear: Service and Repair Special Tool(s) Removal 1. Place front wheels in the straight ahead position. Do not lock the steering column. 2. Remove the front wheel and tire assemblies. 3. Remove the radiator air deflector. 1 Remove the bolts. 2 Remove the radiator air deflector. 4. Remove the power steering cooler. 5. Loosen the LH tie-rod end jam nut. 6. Remove the cotter pins and the castellated nuts. ^ Discard the cotter pins. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7979 7. CAUTION: Do not damage the tie-rod end dust boot when installing the special tool. NOTE: Remove the adapter from the ball end of the special tool. Apply a small amount of grease to the tie-rod end stud and the ball of the special tool. Using the special tool, separate the tie-rod ends from the knuckles. 8. Remove the LH tie-rod end. ^ Count and record the number of turns required to remove the tie-rod end. 9. Remove the front stabilizer bar. ^ Mark the driver side end of the stabilizer bar for correct installation. 10. Rotate the steering column shaft to access the intermediate shaft pinch bolt. Remove the pinch bolt. 11. Lower the vehicle. 12. Turn the steering wheel back to the straight ahead position. Turn the ignition key to the locked position. 13. Raise the vehicle. 14. CAUTION: Do not allow the steering column intermediate shaft to rotate while the shaft is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. Disconnect the intermediate shaft from the steering gear input shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7980 15. Remove the nut and disconnect the power steering lines. ^ Drain the fluid into a suitable container. ^ Install new O-ring seals. 16. Plug the ends of the fluid lines and ports in the steering gear to prevent damage and entry of dirt. 17. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. Remove the nuts. 18. Remove the stud bolts and washers. 19. Remove the steering gear to crossmember insulator bushings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7981 20. Rotate the steering gear control valve housing toward the front of the vehicle. 21. Turn the steering gear input shaft to the right until the stop is reached. 22. Move the steering gear as far to the RH side of the vehicle as possible. 23. Move the LH front wheel spindle tie-rod forward to clear the frame crossmember. 24. Remove the steering gear from the vehicle. Installation All vehicles 1. NOTE: Make sure the steering gear input shaft is turned to the left until the stop is reached. NOTE: Handle the steering gear with caution to avoid damage to the fluid transfer tubes and to avoid dimples in the tie-rod boots. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7982 Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns. 2. NOTE: Make sure the steering gear control valve housing is turned toward the front of the vehicle. Install the steering gear into the RH opening of the crossmember. 3. Move the steering gear as far to the RH side of the vehicle as possible. 4. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position. 5. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously. 6. Rotate the steering gear control valve housing toward the rear of the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7983 7. Install the steering gear to crossmember insulator bushings as shown. ^ The large end of the metal sleeve must be positioned downward. ^ Check that the mounting surfaces on the crossmember are clean and free of foreign material. 8. Install the steering gear to crossmember washers and stud bolts. ^ The dished side of the washers face down. Vehicles with E-coated frame 9. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. NOTE: The steering gear mounting bolts and nuts will have two different tightening specifications based upon the type of frame coating that is used. The E-coated frame is black and very smooth. The wax-coated frame is gray and very sticky. Install the nuts. Vehicles with wax-coated frame Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7984 10. Install the nuts. All vehicles 11. Install the lines and clamp plate. 12. CAUTION: Do not allow the steering column intermediate shaft to rotate while the shaft is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. Connect the intermediate shaft to the steering gear input shaft. Install the pinch bolt. 13. Install the power steering fluid cooler. 14. Install the front stabilizer bar. ^ Orientate the front stabilizer bar as noted during removal. 15. Install the LH tie-rod end on the front wheel spindle tie-rod. ^ Rotate the tie-rod end the number of turns recorded during removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7985 16. Connect the tie-rod ends to the steering knuckles. 1 Position the tie-rod ends on the steering knuckles. 2 Install the castellated nuts. 3 Install the new cotter pins. ^ Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot seals. 17. Tighten the tie-rod jam nuts. 18. Install the radiator air deflector. 1 Position the radiator air deflector. 2 Install the bolts. 19. Install the front wheel and tire assemblies. 20. Prove out the Supplemental Restraint System (SRS). 21. Fill, purge and leak check the power steering system. 22. Check the wheel alignment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Lower intermediate shaft pinch bolt 36 ft.lb Intermediate shaft to lower intermediate shaft bolt 30-40 ft.lb Upper intermediate shaft to steering column bolt 19-25 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 7997 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 8003 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8004 Steering Wheel: Specifications Steering wheel turning 10 ft.lb Steering wheel rotation sensor bolts 10 ft.lb Steering wheel bolt 25-34 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8005 Steering Wheel: Service Precautions WARNINGS: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generate combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components, whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8006 Steering Wheel: Service and Repair Special Tool(s) WARNINGS: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generate combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components, whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Removal NOTE: Make sure the wheels are in the straight-ahead position. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8007 To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery cable and wait at least one minute. 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the air bag sliding contact electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8008 6. Attach the restraint system diagnostic tool to the vehicle harness side of the air bag sliding contact electrical connector at the base of the steering column. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tool connected to the vehicle harness side of the air bag sliding contact at the base of the steering column, prove out the air bag system 9. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery cable and wait at least one minute. 10. Remove the two steering wheel back cover plugs. 11. Remove the two driver air bag module retaining bolts. 12. Remove the driver air bag module. ^ Disconnect the driver air bag module electrical connector. ^ Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8009 13. Disconnect the steering wheel accessory electrical connector. 14. Remove and discard the steering wheel bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8010 15. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the 2-Jaw Puller or Steering Wheel Puller, as appropriate, to remove the steering wheel. 16. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. Installation 1. Position the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. 2. Install a new steering wheel bolt. 3. Connect the steering wheel accessory electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8011 4. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Remove the restraint system diagnostic tool from the vehicle harness side of the air bag sliding contact electrical connector at the base of the steering column. 5. Connect the air bag sliding contact electrical connector at the base of the steering column. 6. Connect the restraint system diagnostic tool to the air bag sliding contact electrical connector at the top of the steering column. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tool connected to the air bag sliding contact electrical connector at the top of the steering column, prove out the air bag system. 9. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8012 10. Remove the restraint system diagnostic tool from the air bag sliding contact electrical connector at the top of the steering column. 11. Position the driver airbag module to the steering wheel. 1 Connect the driver air bag module electrical connector. 2 Position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8013 14. Position the lower steering column opening finish panel reinforcement and install the bolts. 15. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 16. Position the hood release handle and install the screws. 17. Connect the battery ground cable. 18. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With the restraint system diagnostic tool removed, prove out the air bag system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie-rod end nut 44-59 ft.lb Tie-rod end to spindle castellated nuts 66 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8023 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8024 Ball Joint: Specifications Lower Ball joint Radial Play 1/32 inch Front Suspension arm lower ball joint nut 83-112 ft. lbs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8025 Ball Joint: Specifications Upper ball joint radial play - maximum 1/32 inch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8028 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8029 Ball Joint: Testing and Inspection Ball Joint, Lower Ball Joint Inspection 1. Raise and support the vehicle. 2. Prior to carrying out any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front suspension lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Install a new ball joint as necessary. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8030 Ball Joint: Testing and Inspection Ball Joint, Upper Ball Joint Inspection 1. Raise and support the vehicle. 2. Prior to carrying out any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be tested. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front suspension upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper ball joint or loose pinch bolt joint. Tighten pinch bolt and nut as necessary. Install a new upper ball joint as necessary. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8031 Ball Joint: Service and Repair Ball Joint-Lower Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel and tire assembly. 3. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support. Remove the caliper support bracket bolts, then position the caliper and support bracket aside. 4. Disconnect the front anti-lock brake sensor (ABS) wire from the vehicle frame. 1. Disconnect the ABS electrical connector. 2. Unclip the front ABS wire from the vehicle frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8032 5. Using a suitable jack, support the front suspension lower arm. 6. Remove the tie-rod end castellated nut. ^ Remove and discard the cotter pin and the castellated nut. 7. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate the tie-rod end from the front wheel knuckle. 8. Remove the lower ball joint castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8033 9. Using the special tool, separate the front wheel knuckle from the front suspension lower arm. Then, loosely install the lower ball joint castellated nut. 10. Remove the pinch bolt and nut. 11. Remove the hand-tightened lower ball joint castellated nut, then remove the front wheel knuckle. 12. Remove the snap ring from the ball joint. Discard the snap ring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8034 13. Using a suitable ball joint remover tool, remove the ball joint. 14. CAUTION: Do not damage the ball joint boot when installing the special tool. NOTE: Clean and inspect the control arm ball joint bore for damage before installing a new ball joint. NOTE: Make sure the new ball joint snap ring is fully seated. To install, reverse the removal procedure. ^ Always install new castellated nuts and cotter pins. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications Control Arm: Specifications Suspension upper arm cam nuts Front 98 ft.lb Upper Control arm to frame mounting bolts and nuts 83-113 ft.lb Lower Control arm to frame mounting bolts and nuts 140 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm: Service and Repair Lower Special Tool(s) Special Tool(s) Removal 1. Remove the wheel and tire assembly. 2. Remove the stabilizer link nut, washer and bushing. 3. Remove the front shock absorber-to-front suspension lower arm nuts. 4. Remove the torsion bar. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 8040 5. Remove the lower ball joint castellated nut. 1 Remove the lower ball joint cotter pin. 2 Remove the lower ball joint castellated nut. 6. Use the Pitman Arm Puller to separate the front suspension lower arm from the front wheel knuckle/spindle. 7. Remove the front suspension lower arm. 1 Remove the front suspension lower arm bolts and nuts. 2 Remove the front suspension lower arm. Installation All vehicles 1. NOTE: Tighten the front suspension lower arm pivot bolts and nuts until snug. Do not tighten to specification until the installation procedure is complete. NOTE: Inspect the front suspension lower arm ball joints and boot seals for damage. Install the front suspension lower arm. 1 Position the front suspension lower arm to the front suspension crossmember. 2 Install the pivot bolts and nuts and tighten until snug. 2. CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so will cause damage to the wheel and tire assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 8041 Connect the front suspension lower arm to the front wheel knuckle/spindle. 1 Position the lower ball joint into the front wheel knuckle/spindle. 2 Install the new castellated nut. 3 Install a new cotter pin. 3. Install the front shock absorber-to-front suspension lower arm nuts. 4. Install the stabilizer link bushing, washer, and nut. 5. NOTE: Whenever the torsion bar or torsion bar adjuster is removed, the vehicle ride height must be checked. Install the torsion bar. 6. Install the tire and wheel assembly. Vehicles with E-coated frame Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 8042 7. NOTE: The lower arm inboard mounting bolts and nuts will have two different specifications based upon the type of frame coating that is used. The E-coated fume is black and very smooth. The wax-coated frame is gray and very sticky. Tighten the lower arm nuts. Vehicles with wax-coated frame 8. Tighten lower arm nuts. All vehicles 9. Inspect and adjust the front end alignment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 8043 Control Arm: Service and Repair Upper Removal 1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Use a suitable jack stand to support the front suspension lower arm. 4. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it from tilting before removing the pinch bolt and nut. Remove the pinch bolt and nut from the front wheel spindle. 5. Remove the front suspension upper arm. 1 Remove the two nuts. 2 Remove the two bolts. 3 Remove the front suspension upper arm. Installation 1. Install the front suspension upper arm. 1 Position the front suspension upper arm. 2 Install the two bolts and two nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 8044 2. Install the pinch bolt and nut to the front wheel spindle. 1 Position the front wheel spindle. 2 Install the pinch bolt and nut. 3. Remove the jack stand from under the front suspension lower arm. 4. Install the tire and wheel assembly. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Inspect the front end ride height. 7. Inspect and adjust the front end alignment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Front Wheel Spindle Tie-Rod Ball Socket 89 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 8048 Front Steering Knuckle: Service and Repair Special Tool(s) Special Tool(s) Removal 1. Remove the brake disc and hub. 2. Remove the front brake anti-lock sensor. 1 Remove the anti-lock sensor electrical wire from the clamp. 2 Remove the bolt and position the sensor aside. 3. Remove the tie-rod end castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 8049 4. Use the Pitman Arm Puller to separate the tie-rod end from the front wheel spindle. 5. Use a suitable jack stand to support the front suspension lower arm. 6. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it from tilting before removing the pinch bolt and nut. Remove the pinch bolt and nut from the front wheel spindle. 7. Remove the lower ball joint castellated nut. 1 Remove the lower ball joint cotter pin. 2 Remove the lower ball joint castellated nut. 8. Use the Pitman Arm Puller to remove the front wheel spindle. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 8050 1. NOTE: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so can cause damage to the wheel and tire assembly. Install the lower ball joint castellated nut. 1 Position the front wheel spindle to the lower ball joint. 2 Install the lower ball joint castellated nut. 3 Install a new cotter pin. 2. Install the pinch bolt and nut. 1 Position the front wheel spindle. 2 Install the pinch bolt and nut. 3. Remove the jack from under the front suspension lower arm. 4. CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so can cause damage to the wheel and tire assembly. Connect the tie-rod end to the front wheel spindle. 1 Position the tie-rod end. 2 Install the tie-rod end castellated nut. 3 Install a new cotter pin. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 8051 5. Install the front brake anti-lock sensor and position the anti-lock sensor electrical wire in the clamp. 6. Install the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-21-3 > Nov > 04 > Suspension - Rear Suspension Squeaking Noise Stabilizer Link: Customer Interest Suspension - Rear Suspension Squeaking Noise TSB 04-21-3 11/01/04 SQUEAKING NOISE FROM REAR SWAY BAR LINK FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a squeaking noise from the rear suspension, which is especially noticeable when driving over bumps. The noise may be coming from the rear stabilizer bar link bushing(s). ACTION Confirm the source of the noise by jouncing the rear of the vehicle up and down, by pushing on the rear bumper. Replace the rear stabilizer bar link(s) with revised part and attachment nut(s). Torque to new specification of 55 lb-ft (75 N.m). Refer to Workshop Manual Section 204-02. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042103A Replace One Rear 0.4 Hr. Stabilizer Bar Link 042103B Replace Both Rear 0.5 Hr. Stabilizer Bar Links DEALER CODING CONDITION BASIC PART NO. CODE 5K484 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-21-3 > Nov > 04 > Suspension - Rear Suspension Squeaking Noise Stabilizer Link: All Technical Service Bulletins Suspension - Rear Suspension Squeaking Noise TSB 04-21-3 11/01/04 SQUEAKING NOISE FROM REAR SWAY BAR LINK FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a squeaking noise from the rear suspension, which is especially noticeable when driving over bumps. The noise may be coming from the rear stabilizer bar link bushing(s). ACTION Confirm the source of the noise by jouncing the rear of the vehicle up and down, by pushing on the rear bumper. Replace the rear stabilizer bar link(s) with revised part and attachment nut(s). Torque to new specification of 55 lb-ft (75 N.m). Refer to Workshop Manual Section 204-02. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042103A Replace One Rear 0.4 Hr. Stabilizer Bar Link 042103B Replace Both Rear 0.5 Hr. Stabilizer Bar Links DEALER CODING CONDITION BASIC PART NO. CODE 5K484 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications Spring Shackle Lower Bolt and Nut Rear 85 ft.lb Spring to front frame Bracket and nut (E-coated frame) 85 ft.lb Spring to front frame bracket bolt and nut (wax-coated frame) 111 ft.lb Spring U-bolt nut 76 ft.lb Jounce Bumper nut 15-21 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8069 Suspension Spring ( Coil / Leaf ): Service and Repair Spring Tools Special Tool(s) Removal and Installation All vehicles 1. Remove the wheel and tire assembly. 2. Use the High-Lift Jack to support the rear axle. 3. Separate the rear spring from the rear axle. 1 Remove the nuts. 2 Remove the U-bolts. 3 Position the rear spring plate aside. Vehicles with E-coated frame Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8070 4. NOTE: The leaf spring forward mounting bolt will have two different tightening specifications based upon the type of frame coating that is used. The E-coated frame is black and very smooth. The wax-coated frame is gray and very sticky. Remove the bolts, nuts and the rear spring. Vehicles with wax-coated frame 5. Remove the nuts, bolts and the rear spring. All vehicles 6. To install, reverse the removal procedure. ^ Use new fasteners. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications Shock absorber-to-frame nuts Front 17 ft.lb Shock absorber lower bolt 46 ft.lb Shock to frame mounting nut 30-41 ft.lb Shock absorber to lower arm nuts 15-21 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications Torsion Bar: Specifications Torsion bar cover plate bolts 35-46 ft.lb Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8077 Torsion Bar: Service and Repair Special Tool(s) Removal 1. Raise the vehicle on a hoist. 2. Remove the torsion bar cover plate. 1 Remove the torsion bar cover plate bolts. 2 Remove the torsion bar cover plate. 3. NOTE: Before relieving the torsion bar tension, measure and record the measurement of the torsion bar adjustment bolt. This measurement will be used as the preset depth for the new torsion bar adjustment bolt during installation. Make preliminary adjustment references. ^ Measure and record the length where indicated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8078 4. Relieve the torsion bar tension. 1 Position the Torsion Bar Tool and adapters. 2 Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off the adjustment bolt. 5. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive. A new bolt must be installed if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment. Remove the torsion bar adjustment bolt and nut. 6. Loosen the Torsion Bar Tool until the tension is removed from the torsion bar. 7. Remove the torsion bar. 1 Mark the torsion bar and the adjuster for correct installation. 2 Remove the torsion bar insulator. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8079 3 Grasp the torsion bar, and pull it free from the front suspension lower arm. Installation 1. Position the torsion bar and the torsion bar adjuster. 2. Install the torsion bar adjuster. 1 Align the marks on the torsion bar and the torsion bar adjuster, then install the torsion bar adjuster. 2 Position the torsion bar insulator. 3. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive. A new bolt must be installed if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment. Preload the torsion bar. 1 Install the Torsion Bar Tool and the adapters. 2 Tighten the Torsion Bar Tool until the new adjustment bolt and nut can be installed. 3 Turn the adjustment bolt until the preliminary adjustment measurement (recorded length of the old adjustment bolt) is reached. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8080 4. Install the torsion bar cover plate. 1 Position the torsion bar cover plate. 2 Install the torsion bar cover plate bolts. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Adjust the ride height. 7. Check the alignment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications - Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 8084 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford Wheel Bearing: Service and Repair Ford Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Special Tools Special Tool(s) Removal 1. Remove the axle shaft. 2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford > Page 8087 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Special Tool(s) Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford > Page 8088 NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications - Tighten the spindle nut while rotating the brake disc and hub. - Loosen the spindle nut. - Tighten the spindle nut while rotating the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. ^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL TRANSMISSION). Jacking Points - Front 1. The front jacking point is a tab that extends from the lower control arm. 1. The rear jacking points are located on the rear axle tube. CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8097 Lifting Points - 4x4 1. Locate front and rear hoist adapters on bottom lifting points as indicated. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8106 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8108 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8109 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8110 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8111 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8112 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8113 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8114 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8115 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Tires: Recalls Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8124 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8125 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8126 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8127 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8129 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8130 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8136 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8141 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8143 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8144 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8145 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8146 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8147 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8148 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8149 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8150 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement Technical Service Bulletin # 00L12 Date: 010101 Information 00L12 SPECIAL FIELD ACTION All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Original - January 2001 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Supplement # 1, February 5, 2001 - Updated Information All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Supplement # 2, February 19, 2001 - Updated Information All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8155 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8156 Attachment I - Administrative Information OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Attachment II - Labor Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8157 LABOR ALLOWANCES Attachment III - Technical Information SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico, and Canada, built through December 31, 2000. NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after December 31, 2000. SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8158 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8159 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8160 Supplement # 1 - Information Supplement # 1, February 5, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8161 Attachment III ^ Technical Information Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8162 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8163 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8164 Supplement # 1 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 1 - Attachment II Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8165 LABOR ALLOWANCES Supplement # 1 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8166 SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (included in this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8168 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8169 Supplement # 2 - Information Supplement # 2, February 19, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^Labor Allowances Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8170 Attachment III ^ Technical Information Apology Letter Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8171 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8172 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8173 Supplement # 2 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 2 - Attachment II Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8174 LABOR ALLOWANCES Supplement # 2 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8175 1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8176 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8177 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8178 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8187 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8188 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8189 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8190 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8191 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8192 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8193 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8199 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement Technical Service Bulletin # 00L12 Date: 010101 Information 00L12 SPECIAL FIELD ACTION All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Original - January 2001 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Supplement # 1, February 5, 2001 - Updated Information All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Supplement # 2, February 19, 2001 - Updated Information All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8204 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8205 Attachment I - Administrative Information OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Attachment II - Labor Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8206 LABOR ALLOWANCES Attachment III - Technical Information SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico, and Canada, built through December 31, 2000. NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after December 31, 2000. SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8207 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8208 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8209 Supplement # 1 - Information Supplement # 1, February 5, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8210 Attachment III ^ Technical Information Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8211 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8212 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8213 Supplement # 1 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 1 - Attachment II Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8214 LABOR ALLOWANCES Supplement # 1 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8215 SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (included in this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8216 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8217 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8218 Supplement # 2 - Information Supplement # 2, February 19, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^Labor Allowances Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8219 Attachment III ^ Technical Information Apology Letter Customer Notification Letter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8220 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8221 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8222 Supplement # 2 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 2 - Attachment II Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8223 LABOR ALLOWANCES Supplement # 2 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8224 1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8225 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8226 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8227 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 8228 Tires: Specifications General Specifications Wheel Rim Runout Tire Runout Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 8229 Tires: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the wheel nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1 Remove the wheel nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Clean the wheel hub mounting surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the wheel nuts hand-tight, then lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 8230 3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in a star pattern, using a torque wrench or torque sticks. 4. Install the center cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Wheels: Recalls Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8244 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Wheels: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8254 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 8255 Wheels: Specifications General Specifications Wheel Rim Runout Tire Runout Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire Removal 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the wheel nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1 Remove the wheel nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Clean the wheel hub mounting surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the wheel nuts hand-tight, then lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 8258 3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in a star pattern, using a torque wrench or torque sticks. 4. Install the center cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 8259 Wheels: Service and Repair Wheel Leaks 1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications - Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8263 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford Wheel Bearing: Service and Repair Ford Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Special Tools Special Tool(s) Removal 1. Remove the axle shaft. 2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 8266 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Special Tool(s) Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 8267 NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. ^ For Traction-Lok(R) rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications - Tighten the spindle nut while rotating the brake disc and hub. - Loosen the spindle nut. - Tighten the spindle nut while rotating the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts 135 Nm (100 lb/ft) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal 1. Remove the brake disc and hub. 2. CAUTION: Place shop towels between the pry bars and the brake disc to prevent damage to the disc surface. Using two pry bars, remove the ABS sensor ring. Discard the ABS sensor ring. 3. Using a suitable press, remove the wheel stud from the brake disc and hub. Installation 1. Using a suitable press, install the wheel stud in the brake disc and hub. 2. CAUTION: When installing the ABS sensor ring, make sure the sensor ring is pressed on straight. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 8277 Position a new ABS sensor ring on the hub. Using a cylinder with 79 mm (3.16 inch) inside diameter and 96 mm (3.84 inch) outside diameter, press the ring onto the hub until the ring seats against the shoulder in the hub. 3. Install the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 8278 Wheel Fastener: Service and Repair Rear Special Tool(s) Special Tool(s) Removal CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the rear disc brake caliper, rear disc support bracket and brake disc, if so equipped. Support the rear disc brake caliper with safety wire. 4. Using the C-Frame and Screw Assembly, press the wheel stud from its seat and discard. Installation CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud. 1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned with those made by the original wheel stud. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 8279 2. Seat new wheel studs in the axle flange. - Place four flatwashers over the outside end of the wheel stud. - Thread a standard wheel nut with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the flange. 3. Remove the wheel nut and flatwashers. 4. Install the brake disc, rear disc support bracket and the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions Accumulator HVAC: Service Precautions CAUTION: Use a back-up wrench to prevent damage to the tubes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 8284 Accumulator HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. Suction Accumulator, Part 1 Suction Accumulator, Part 2 The suction accumulator is mounted on the A/C accumulator bracket to the right of the vehicle centerline. The inlet tube of the suction accumulator attaches directly to the A/C evaporator core outlet tube and the outlet tube attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator, the heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 8285 and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the top of the suction accumulator is used to attach the A/C cycling switch. A long-travel Schrader- type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 8286 Accumulator HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for suction accumulator/drier removal. 1 Disconnect the battery ground cable. 2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 3 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and the nuts. 2 Position the coolant expansion tank/windshield washer reservoir aside. 4. Disconnect the A/C cycling switch electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 8287 5. Disconnect the suction accumulator/drier refrigerant lines. CAUTION: Use a back-up wrench to prevent damage to the tubes. 6. Remove the two screws and the suction accumulator/drier. INSTALLATION 1. To install, reverse the removal procedure. - If a new suction accumulator/drier is to be installed, transfer the A/C cycling switch to the new suction accumulator/drier. - If a new suction accumulator/drier is to be installed, refer to refrigerant oil addition. See: Refrigerant Oil Addition. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 8288 Accumulator HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 8296 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 8297 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 8298 Air Door Actuator / Motor: Service Precautions CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Motor Air Door Actuator / Motor: Description and Operation Blend Door Motor The A/C electronic blend door actuator is located on the rear of the A/C evaporator housing. - Its function is to move the air temperature blend doors on command from the temperature control switch. - The A/C electronic blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Motor > Page 8301 Air Door Actuator / Motor: Description and Operation Vacuum Control Motors The vacuum control motors: - are located on the A/C evaporator housing, A/C recirculating air duct and heater air plenum chamber. - direct system airflow to the vehicle interior as determined by the function selector switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor Air Door Actuator / Motor: Service and Repair Blend Door Motor REMOVAL 1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair " See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the A/C electronic door actuator motor. - Remove the screws. - Disconnect the harness connector and remove the A/C electronic door actuator motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 8304 Air Door Actuator / Motor: Service and Repair Air Door Actuator / Motor, HVAC Air Recirculation Door Vacuum Control Motor REMOVAL 1. Release the stops and lower the glove compartment door to the floor. 2. Remove the screws and disconnect the vacuum hose. 3. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Panel/Defrost Door Vacuum Control Motor REMOVAL 1. Disconnect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 8305 2. Remove the lower steering column opening finish panel. 1 Remove the screws. Detach the hood release handle. 2 Remove the two screws. 3 Pull out to release the retaining clips. Remove the lower steering column opening finish panel. 3. Remove the bolts and the lower steering column opening finish panel reinforcement. 4. Remove the two screws. Detach the relay panel. 5. Remove the screws. Disconnect the vacuum hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 8306 6. Rotate the vacuum control motor. Disengage the lever and remove the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Panel/Floor Door Vacuum Control Motor REMOVAL 1. Remove the lower steering column opening finish panel. 1 Remove the screws. Detach the hood release handle. 2 Remove the two screws. 3 Pull out to release the retaining clips. Remove the lower steering column opening finish panel. 2. Remove the bolts and the lower steering column opening finish panel reinforcement. 3. Remove the two bolts and the floor console mounting bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 8307 4. Remove the screws. Disconnect the vacuum hose. 5. Rotate the vacuum control motor. Disengage the lever and remove the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct Air Duct: Service and Repair Floor Duct REMOVAL 1. Remove the second row climate control assembly. 2. Remove the screws and the rear floor duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 8312 Air Duct: Service and Repair Windshield Defroster and Side Window Demister Nozzle REMOVAL 1. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the two screws and remove the LH demister nozzle and duct. 3. Remove the two screws and remove the RH demister nozzle and duct. 4. Remove the screws and remove the windshield defroster hose nozzle. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 8313 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister Air Register: Service and Repair Defrost Nozzles and Side Demister REMOVAL 1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair " See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the two screws and remove the LH demister nozzle and duct. 3. Remove the two screws and remove the RH demister nozzle and duct. 4. Remove the screws and remove the windshield defroster hose nozzle. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 8318 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 8319 Air Register: Service and Repair Air Register Center REMOVAL 1. Remove the audio unit. 2. Remove the screws. Disengage the spring clips. Detach the instrument panel finish panel. 3. Disconnect the cigar lighter electrical connectors. 4. Disconnect the electrical connectors. Remove the instrument panel finish panel. NOTE: The number and location of the electrical connectors will vary dependent on vehicle equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 8320 5. Release the eight clips. Remove the center instrument panel register from the instrument panel finish panel. INSTALLATION 1. To install, reverse the removal procedure. Driver Side REMOVAL 1. Remove the LH instrument panel finish panel. 2. Remove the LH instrument panel register. 1 Remove the screws. 2 Remove the LH instrument panel register. INSTALLATION 1. Follow the removal procedure in reverse order. Passenger Side REMOVAL Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 8321 1. Lift the edge of the RH instrument panel register to expose the retainers. 2. Release the retainers and remove the RH instrument panel register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8325 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8328 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8329 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8330 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8331 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8332 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8333 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8344 Blower Motor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8345 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8346 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8347 Blower Motor: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 Blower Motor: Electrical Diagrams DETAILED DIAGRAMS Diagram 412-00-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 Diagram 412-00-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8350 Diagram 412-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8351 Diagram 412-00-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8352 Diagram 412-00-00-5 RELATED DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8353 Diagram 413-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8354 Diagram 413-00-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8355 Blower Motor: Service Precautions CAUTION: Do not attempt to bend the second row climate control assembly arm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8356 Blower Motor: Description and Operation The blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8357 Blower Motor: Testing and Inspection For further information regarding this component please refer to: Heating and Air Conditioning; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor: Service and Repair Front Blower Motor - Front REMOVAL 1. Prepare the vehicle for blower motor removal. 1 Disconnect the battery ground cable. 2 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and the nuts. 2 Position the coolant expansion tank/windshield washer reservoir aside. 4. Remove the blower motor. 1 Disconnect the vent hose. 2 Disconnect the electrical connector. 3 Remove the four screws. 4 Remove the blower motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8360 Blower Motor: Service and Repair Second Row Blower Motor - Second Row REMOVAL 1. Remove the floor console. 2. Remove the coin tray. 3. Remove the screws and the console insert. 4. Remove the screw and the console lid. 5. Remove the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8361 6. Open the rear cupholder. Remove the screws. 7. Remove the two screws. 8. Disengage the retaining clips. Remove the console rear finish panel. 9. Remove the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8362 10. Disconnect the electrical connectors. Disengage the pin-type retainer. 11. Disconnect the air distribution door linkage from the second row climate control assembly arm. Remove the second row climate control assembly. CAUTION: Do not attempt to bend the second row climate control assembly arm. 12. Remove the screws and the console rear air distribution duct. 13. Remove the nine screws and the console liner. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8363 14. Remove the nuts. 15. Remove the screws. 16. Remove the two screws. 17. Disconnect the blower motor resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8364 18. Disengage the pin-type retainer. 19. Slide the console reinforcement rearward. Partially remove the blower motor and air distribution duct assembly. 20. Disconnect the blower motor electrical connector. 21. Remove the screws. Remove the blower motor assembly from the console air distribution duct. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8365 1. Align the blower motor assembly with the console air distribution duct. Install the screws. 2. Connect the blower motor electrical connector. 3. Position and align the studs of the blower motor and air distribution duct assembly to the console reinforcement. 4. Slide the console reinforcement forward. 5. Engage the pin-type retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8366 6. Connect the blower motor resistor electrical connector. 7. Install the two screws. 8. Install the two screws. 9. Install the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8367 10. Install the console liner and the nine screws. 11. Install the console rear air distribution duct and the screws. 12. Connect the air distribution door linkage to the second row climate control assembly arm. CAUTION: Do not attempt to bend the second row climate control assembly arm. 13. Connect the electrical connectors. Engage the pin-type retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8368 14. Position the second row climate control assembly. Install the screws. 15. Align the console rear finish panel to the floor console. Engage the retaining clips. 16. Install the screws. 17. Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 8369 18. Install the screws. 19. Install the console lid and the screw. 20. Install the console insert and the screws. 21. Install the coin tray. 22. Install the floor console. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Diagram 700-01-00-2 Diagram 700-01-00-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 8373 Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 8374 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay > Page 8377 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Page 8378 Blower Motor Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Page 8379 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8383 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front > Page 8386 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 8387 Blower Motor Resistor: Description and Operation The front heater blower motor switch resistor has the following features: - The assembly is located in the engine compartment on the evaporator housing next to the blower motor assembly. - Three resistor elements are mounted on the resistor board to provide four blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. - An overheating device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F), interrupting the blower motor operation in all speeds except high. - The thermal limiter cannot be reset and is not serviceable. The second row heater blower motor switch resistor has the following features: - The assembly is located in the high-series flow-through floor console next to the blower motor assembly. - There is one resistor element are mounted on the resistor board to provide two blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. - An overheating device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F), interrupting the blower motor operation in all speeds. - The thermal limiter cannot be reset and is not serviceable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front Blower Motor Resistor: Service and Repair Front Blower Motor Resistor - Front REMOVAL 1. Prepare the vehicle for heater blower motor switch resistor removal. 1 Disconnect the battery ground cable. 2 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3 Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and nuts. 2 Position the reservoir aside. 4. Disconnect the heater blower motor switch resistor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front > Page 8390 5. Remove the screws and the heater blower motor switch resistor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front > Page 8391 Blower Motor Resistor: Service and Repair Second Row Blower Motor Resistor - Second Row REMOVAL 1. Remove the floor console. 2. Disconnect the heater blower motor switch resistor electrical connector. 3. Remove the screws and the heater blower motor switch resistor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams Blower Motor Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Page 8395 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Page 8396 Blower Motor Switch: Description and Operation Function Selector Switch The function selector switch combines a vacuum selector valve with two electrical switches to supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit. Temperature Control Switch Temperature selection is accomplished with a potentiometer connected to the electric blend door. Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a corresponding movement on the air temperature that the air system will maintain. Blower Motor Switch The blower motor switch controls blower motor speed by adding or by passing resistors in the heater blower motor switch resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Page 8397 Blower Motor Switch: Service and Repair CLIMATE CONTROL ASSEMBLY-FRONT SWITCHES REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air Gap Between Pulley And Clutch Plate .......................................................................................................................... 0.35-0.75 mm (0.014-0.030 in) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions Compressor Clutch: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8407 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8408 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8409 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8410 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8411 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8417 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 Compressor Clutch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 Compressor Clutch: Electrical Diagrams DETAILED DIAGRAMS Diagram 412-00-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 Diagram 412-00-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 Diagram 412-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 Diagram 412-00-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 Diagram 412-00-00-5 RELATED DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 Diagram 413-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 Diagram 413-00-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8433 Compressor Clutch: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8434 Compressor Clutch: Description and Operation NOTE: - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley , A/C clutch field coil and the shaft seal are serviceable. - Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The magnetic A/C clutch has the following characteristics: - It drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the A/C clutch is drawn toward the A/C clutch pulley. - The magnetic force locks the A/C clutch and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. - When B+ is removed from the A/C clutch field coil, springs in the A/C clutch move the A/C clutch away from the A/C clutch pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8435 Compressor Clutch: Testing and Inspection For further information regarding this component please refer to: Heating and Air Conditioning; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8436 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally-spaced places between the A/C clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8437 Compressor Clutch: Service and Repair Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8438 2. Remove the bolt. 1 Hold the A/C clutch hub with the special tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8439 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the special tool on the nose opening of the A/C compressor. 3 Install the special tool. 4 Remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley bearing mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 2 Place the special tool on the A/C clutch field coil. 3 Place the special tool on the special tool. 4 Use the special tool to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8440 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the special tool. 2 Tighten the bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8441 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 8442 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 8446 Compressor Clutch Coil: Service and Repair Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 8447 2. Remove the bolt. 1 Hold the A/C clutch hub with the special tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 8448 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the special tool on the nose opening of the A/C compressor. 3 Install the special tool. 4 Remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley bearing mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 2 Place the special tool on the A/C clutch field coil. 3 Place the special tool on the special tool. 4 Use the special tool to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 8449 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the special tool. 2 Tighten the bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 8450 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 8451 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions Compressor Shaft Seal: Service Precautions CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8455 Compressor Shaft Seal: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8456 2. Remove the shaft seal felt from the nose of the A/C compressor with the special tool. 3. Clean the compressor nose area. 4. Insert the tip of the special tool into one of the snap ring eyes. 5. Rotate the special tool to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the special tool up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8457 7. Engage the special tool into the inside diameter of the shaft seal. 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with PAG oil or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8458 3. Position the shaft seal and the special tool over the A/C compressor shaft. 4. Push the shaft seal onto the A/C compressor shaft with the special tool until seated. 5. Install the shaft seal snap ring. 6. Carry out the A/C Compressor External Leak Test. See: Testing and Inspection/External Leak Test 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8459 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8463 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8464 Compressor Clutch Relay: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8465 Compressor Clutch Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8466 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Description and Operation Compressor Fitting HVAC: Description and Operation The A/C manifold and tube is attached to the A/C compressor, is sealed with O-ring seals, and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure cutoff switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cutoff switch can be removed without discharging the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Description and Operation > Page 8470 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for A/C manifold and tube removal. 1 Disconnect the battery ground cable. 2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 3 Remove the air cleaner assembly. 4 Remove the A/C compressor. 2. Disconnect the A/C pressure cut-off switch electrical connector. 3. Disconnect the A/C manifold and tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 4. Disconnect the A/C manifold and tube spring lock coupling. - During installation, install new O-ring seals lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 5. Raise and support the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Description and Operation > Page 8471 6. Remove the bolt. Detach the A/C manifold and tube. 7. Lower the vehicle. 8. Remove the A/C manifold and tube from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. - If a new A/C manifold and tube is to be installed, transfer the A/C pressure cut-off switch to the new A/C manifold and tube. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Description and Operation > Page 8472 Compressor Fitting HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Description and Operation > Page 8473 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The A/C condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and condense refrigerant gas to liquid refrigerant as it is cooled. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 8477 Condenser HVAC: Testing and Inspection On-Vehicle Leak Test 1. Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low Pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 8478 Condenser HVAC: Service and Repair REMOVAL NOTE: - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. - If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it is removed from the vehicle. 1. Prepare the vehicle for A/C condenser core removal. 1 Disconnect the battery ground cable. 2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 3 Remove the air cleaner assembly. 2. Disconnect the A/C manifold and tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 4. Raise the vehicle. 5. Remove the lower air deflector. 1 Remove the seven screws. 2 Remove the two pin-type retainers and the air deflector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 8479 6. Remove the metallic Clip. Detach the transmission oil cooler lines. 7. Remove the bolt. 8. Remove the bolt and the A/c condenser core. INSTALLATION 1. To install, reverse the removal procedure. - If a new A/C condenser core is to be installed, refer to refrigerant oil addition. See: Refrigerant Oil Addition. - If a new A/C condenser core is to be installed, a new A/C evaporator core orifice should also be installed. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 8480 Condenser HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 8481 Special Tool(s) Set, A/C Fittings Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8485 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 Control Assembly: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 Control Assembly: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 Control Assembly: Electrical Diagrams DETAILED DIAGRAMS Diagram 412-00-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 Diagram 412-00-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 Diagram 412-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 Diagram 412-00-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 Diagram 412-00-00-5 RELATED DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 Diagram 413-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 Diagram 413-00-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 Control Assembly: Vacuum and Vapor Hose Diagrams Vacuum Schematic-Manual Climate Control System, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 Vacuum Schematic-Manual Climate Control System, Part 2 Vacuum Connector End View - Manual A/C Vacuum Application Chart-Manual A/C Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Main Climate Control Control Assembly: Description and Operation Main Climate Control The climate control assembly has three system controls: 1. Function Selector Switch The function selector switch combines a vacuum selector valve with two electrical switches to supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit. 2. Temperature Control Switch Temperature selection is accomplished with a potentiometer connected to the electric blend door. Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a corresponding movement on the air temperature that the air system will maintain. 3. Blower Motor Switch The blower motor switch controls blower motor speed by adding or by passing resistors in the heater blower motor switch resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Main Climate Control > Page 8520 Control Assembly: Description and Operation Temperature Control Switch Temperature Control Switch Temperature selection is accomplished with a potentiometer connected to the electric blend door. Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a corresponding movement on the air temperature that the air system will maintain. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > System Testing Control Assembly: Testing and Inspection System Testing For further information regarding this component please refer to : Heating and Air Conditioning; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > System Testing > Page 8523 Control Assembly: Testing and Inspection Component Tests Vacuum Schematic-Manual Climate Control System, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > System Testing > Page 8524 Vacuum Schematic-Manual Climate Control System, Part 2 Vacuum Connector End View - Manual A/C Vacuum Application Chart-Manual A/C Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control Control Assembly: Service and Repair Main Climate Control REMOVAL 1. Remove the audio unit. 2. Remove the screws. Disengage the spring clips. Detach the instrument panel finish panel. 3. Disconnect the cigar lighter electrical connectors. 4. Disconnect the electrical connectors. Remove the instrument panel finish panel. NOTE: The number and location of the electrical connectors will vary dependent on vehicle equipment. 5. Remove the screws and the climate control assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 8527 6. Disconnect the climate control assembly. - Disconnect the electrical connectors. - Disconnect the vacuum harness connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 8528 Control Assembly: Service and Repair Auxiliary Climate Control REMOVAL 1. Remove the floor console. 2. Remove the coin tray. 3. Remove the screws and the console insert. 4. Remove the screw and the console lid. 5. Remove the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 8529 6. Open the rear cupholder. Remove the screws. 7. Remove the two screws. 8. Disengage the retaining clips. Remove the console rear finish panel. 9. Remove the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 8530 10. Disconnect the electrical connectors. Disengage the pin-type retainer. 11. Disconnect the air distribution door linkage from the second row climate control assembly arm. Remove the second row climate control assembly. CAUTION: Do not attempt to bend the second row climate control assembly am. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 8531 Control Assembly: Service and Repair Control Assembly Bulbs REMOVAL 1. Remove the climate control assembly. 2. Turn and pull the lamp socket. - Install a new bulb in the socket. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 8532 Control Assembly: Service and Repair Temperature Control Switch CLIMATE CONTROL ASSEMBLY-FRONT SWITCHES REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 8537 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 8538 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting > Page 8543 Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 8544 Coupler HVAC: Service Precautions CAUTION: - Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. - Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. - Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. - Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. - Support the female fitting with a wrench to prevent the tubes from twisting. - Use only new purple O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Spring Lock Coupling Coupler HVAC: Description and Operation Spring Lock Coupling Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. - When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. - The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. - Three O-ring seals are used to seal between the two halves of the spring lock couplings. - These O-ring seals are green in color and are made of special material. - Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring may be used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Spring Lock Coupling > Page 8547 Coupler HVAC: Description and Operation Peanut Fitting The A/C condenser core uses the peanut shaped refrigerant fittings instead of spring lock couplings. - The male and female blocks of the peanut fitting are retained with a nut. - An O-ring seal is installed around the tube on the male block. - The female block is welded to the tube and is not adjustable. - Support the female fitting with a wrench to prevent twisting of the tubes. - The male block will pivot around the tube to allow for alignment with the female block during assembly. - When correctly assembled the male and female fittings should be flush. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure Coupler HVAC: Service and Repair Spring Lock Coupling Connect and Disconnect Procedure Spring Lock Coupling SPECIAL TOOL(S) DISCONNECT 1. Remove the A/C tube lock coupling clip, if equipped. 2. Fit the special tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8550 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8551 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component. 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8552 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with FAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 3. Install the O-ring seals. - Lubricate the O-ring seals with FAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8553 5. Install the A/C tube lock coupling clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8554 Coupler HVAC: Service and Repair Peanut Fitting Connect and Disconnect Procedure DISCONNECT 1. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 2. Pull the peanut fitting apart. 3. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8555 2. Install the O-ring seal. - Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new purple O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When correctly assembled, the male and female fittings should be flush. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation Evaporator Case: Description and Operation The evaporator core housing is located in the engine compartment. The A/C evaporator housing assembly contains the following major components: - A/C evaporator core - blower motor - blower motor resistor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 8559 Evaporator Case: Service and Repair REMOVAL NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. Replacement of the suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. 1. Remove the suction accumulator, please refer to Heating and Air Conditioning/ See: Accumulator HVAC 2. Disconnect the blower motor and the blower motor resistor electrical connectors. 3. Detach the windshield wiper fluid hose. Using suitable hose pinching pliers, disconnect the heater hoses. 4. Detach the heater control valve vacuum hose. 5. Disconnect the heater control valve vacuum hose and the vacuum supply hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 8560 6. Disconnect the condenser to evaporator tube spring lock coupling. 7. Disconnect the vacuum harness connector. Remove the nut. 8. Remove two nuts, one bolt, and the A/C evaporator housing. - Remove the nut located at the bottom of the A/C evaporator housing first. - To remove the A/C evaporator housing, rotate the A/C evaporator housing counterclockwise. Then tip the evaporator core end towards the front of the vehicle. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the refrigerant system with the correct amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. See: Refrigerant Oil Addition. - Install new O-ring seals lubricated in amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. - Lubricate the coolant hoses with MERPOL(R) or plain water only, if needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 8561 Evaporator Case: Tools and Equipment Heater Hose Disconnect Tool Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 8562 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation Evaporator Core: Description and Operation NOTE: - The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. - installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. - The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. - Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. - This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8566 Evaporator Core: Testing and Inspection On-Vehicle Leak Test 1. Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low Pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8567 Evaporator Core: Service and Repair REMOVAL NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. 1. Remove the evaporator core housing, please refer to heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 2. Transfer components from the old evaporator core housing to the new evaporator core housing. INSTALLATION 1. Install the evaporator core housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8568 Evaporator Core: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8569 Special Tool(s) Set, A/C Fittings Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 8573 Expansion Block/Orifice Tube: Description and Operation NOTE: A new A/C evaporator core orifice should be installed whenever a new A/C compressor is installed. The A/C evaporator core orifice has the following characteristics: - It is color coded red. - It is located in the A/C evaporator core inlet tube. - It has filter screens located on the inlet and outlet ends of the tube body. - The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. - O-rings on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. - Adjustment or service cannot be made to the A/C evaporator core orifice assembly. A new evaporator core orifice assembly must be installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > With Damaged Evaporator Core Orifice Expansion Block/Orifice Tube: Service and Repair With Damaged Evaporator Core Orifice SPECIAL TOOL(S) REMOVAL 1. Prepare the vehicle for evaporator core orifice removal. 1 Disconnect the battery ground cable. 2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 3 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and the nuts. 2 Position the coolant expansion tank/windshield washer reservoir aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > With Damaged Evaporator Core Orifice > Page 8576 4. Disconnect the condenser to evaporator tube spring lock coupling. 5. Inspect the evaporator core orifice for damage. 6. Screw the end of the special tool into the broken evaporator core orifice. 7. Holding the special tool T-handle stationary, rotate the special tool body to remove the broken evaporator core orifice. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > With Damaged Evaporator Core Orifice > Page 8577 1. Install new O-ring seals on the evaporator core orifice. - Lubricate the new O-ring seals with PAG oil or equivalent. 2. Position the evaporator core orifice in the special tool. 3. Using the special tool, install the evaporator core orifice. 4. Install the coolant expansion tank/windshield washer reservoir. 1 Install the coolant expansion tank/windshield washer reservoir aside. 2 Install the screws and the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > With Damaged Evaporator Core Orifice > Page 8578 5. Install the speed control servo. 1 Install the speed control servo. 2 Install the bolt. 3 Connect the electrical connector. 6. Restore the vehicle to operating condition. 1 Install the air cleaner assembly. 2 Connect the battery ground cable. 3 Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > With Damaged Evaporator Core Orifice > Page 8579 Expansion Block/Orifice Tube: Service and Repair With Serviceable Evaporator Core Orifice SPECIAL TOOL(S) REMOVAL 1. Prepare the vehicle for evaporator core orifice removal. 1 Disconnect the battery ground cable. 2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 3 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and the nuts. 2 Position the coolant expansion tank/windshield washer reservoir aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > With Damaged Evaporator Core Orifice > Page 8580 4. Disconnect the condenser to evaporator tube spring lock coupling. 5. Inspect the evaporator core orifice for damage. 6. Engage the special tool with the evaporator core orifice. 7. Holding the special tool T-handle stationary, rotate the special tool body to remove the evaporator core orifice. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > With Damaged Evaporator Core Orifice > Page 8581 1. Install new O-ring seals on the evaporator core orifice. - Lubricate the new O-ring seals with PAG oil or equivalent. 2. Position the evaporator core orifice in the special tool. 3. Using the special tool, install the evaporator core orifice. 4. Install the coolant expansion tank/windshield washer reservoir. 1 Install the coolant expansion tank/windshield washer reservoir aside. 2 Install the screws and the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > With Damaged Evaporator Core Orifice > Page 8582 5. Install the speed control servo. 1 Install the speed control servo. 2 Install the bolt. 3 Connect the electrical connector. 6. Restore the vehicle to operating condition. 1 Install the air cleaner assembly. 2 Connect the battery ground cable. 3 Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 8583 Expansion Block/Orifice Tube: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Expansion Valve: Locations For further information regarding this component please refer to: Heating and Air Conditioning; Expansion Block/Orifice Tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 8587 Expansion Valve: Service and Repair For further information regarding this component please refer to: Heating and Air Conditioning; Expansion Block/Orifice Tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair Heater Control Valve: Service and Repair REMOVAL 1. Prepare the vehicle for heater water control valve assembly removal. 1 Drain the engine coolant. 2 Remove the air cleaner assembly. 2. Disconnect the vacuum hose and heater hose. 3. Remove the retaining pins. Position the inner fender well access mat out of the way. 4. Disconnect the heater hose. Remove the bolt and the heater water control valve assembly. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water only, if needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8599 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8600 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8606 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8607 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8608 Heater Core: Service Precautions WARNING: - CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8609 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8610 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED ARE IN SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: the heater control valve is not working correctly. - the heater core may have an air pocket. - the heater core may be plugged. - the thermostat is not working correctly. Heater Core-Pressure Test Use Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8611 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8612 Heater Core: Service and Repair REMOVAL 1. Prepare the vehicle for heater core removal. 1 Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 2 Remove the Dash Board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3 Remove the Powertrain Control Module (PCM), please refer to Powertrain Management/Computers and Controls/Engine Control Module/Service and Repair/ See: Powertrain Management/Computers and Control Systems/Powertrain Control Module/Service and Repair NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 2. Remove the PCM heat sink 1 Remove the ground strap screw. 2 Remove the heat sink. 3. Remove the four nuts from the engine side of the dash panel. Position the plenum chamber on the vehicle floor. 4. Remove the heater core cover. 1 Remove the screws. 2 Remove the heater core cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8613 5. Remove the heater core. - During installation, be sure to install a new oval foam seal around the heater core inlet and outlet tubes. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8622 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8623 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8629 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8630 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups. Refer to specifications regarding operating pressure(s). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: Customer Interest A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: All Technical Service Bulletins A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 8647 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 8648 Hose/Line HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for condenser to evaporator tube removal. 1 Disconnect the battery ground cable. 2 Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. 3 Remove the air cleaner assembly. 2. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. Disconnect and remove the condenser to evaporator tube. INSTALLATION 1. To install, reverse the removal procedure. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 8649 Disconnect Tool Set, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for plenum chamber removal. 1 Remove the dash board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2 Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 3 Remove the Powertrain Control Module (PCM), please refer to Powertrain Management/Computers and Controls/Engine Control Module/Service and Repair/ See: Powertrain Management/Computers and Control Systems/Powertrain Control Module/Service and Repair 2. Remove the PCM heat sink. 1 Remove the ground strap screw. 2 Remove the PCM heat sink 3 Remove the four nuts and the plenum chamber. NOTE: To ease the removal of the plenum chamber, first remove the nut located at the center of the dash panel behind the engine cylinder block. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation For further information regarding this component and the system that it is part of, please refer to: Accumulator HVAC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 8656 Receiver Dryer: Service and Repair For further information regarding this component and the system that it is part of, please refer to: Accumulator HVAC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity ............................................................................................................................................... ......................................................... 0.85 kg (30 oz) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8661 Refrigerant: Fluid Type Specifications A/C Refrigerant .................................................................................................................................... ....................................... R-134a Refrigerant YN-19 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Customer Safety Information Refrigerant: Customer Safety Information WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT POSSIBLE PERSONAL INJURY . Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Customer Safety Information > Page 8664 Refrigerant: Environmental Impact Information The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Customer Safety Information > Page 8665 Fax: 215-541-4635 http://www.macsw.org/ Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Customer Safety Information > Page 8666 Refrigerant: Technician Safety Information WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE AIR BAG SYSTEM BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING ANY CLIMATE CONTROL COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. R-134A IS CLASSIFIED AS A SAFE REFRIGERANT, BUT MISUSE CAN MAKE IT DANGEROUS. THE FOLLOWING PRECAUTIONS MUST BE OBSERVED. ALWAYS WEAR SAFETY GOGGLES WHEN REPAIRING AN AIR CONDITIONING SYSTEM. - AVOID CONTACT WITH LIQUID REFRIGERANT R-134A. R-134A VAPORIZES AT APPROXIMATELY -25°C (-13°F) UNDER ATMOSPHERIC PRESSURE AND IT WILL FREEZE SKIN TISSUE. - NEVER ALLOW REFRIGERANT R-134A GAS TO ESCAPE IN QUANTITY IN AN OCCUPIED SPACE. R-134A IS NON-TOXIC, BUT IT WILL DISPLACE THE OXYGEN NEEDED TO SUPPORT LIFE. - NEVER USE A TORCH IN AN ATMOSPHERE CONTAINING R-134A GAS. R-134A IS NON-TOXIC AT ALL NORMAL CONDITIONS, BUT WHEN IT IS EXPOSED TO HIGH TEMPERATURES, SUCH AS A TORCH FLAME, IT DECOMPOSES. ONE OF THE PRODUCTS OF THE CHEMICAL BREAKDOWN IS A PHOSGENE GAS, WHICH IS HIGHLY TOXIC. - DO NOT ALLOW ANY PORTION OF THE CHARGED AIR CONDITIONING SYSTEM TO BECOME TOO HOT. THE PRESSURE IN AN AIR CONDITIONING SYSTEM RISES AS THE TEMPERATURE RISES AND TEMPERATURES OF APPROXIMATELY 85°C (185°F) CAN BE DANGEROUS. - ALLOW THE ENGINE TO COOL SUFFICIENTLY PRIOR TO PERFORMING MAINTENANCE OR SERIOUS BURNS AND INJURY CAN OCCUR. DUE TO REFRIGERANT HAZARDS, ALWAYS WEAR SAFETY GOGGLES AND NON-PENETRABLE GLOVES WHEN WORKING ON OR FLUSHING A/C SYSTEMS. USE EXTREME CARE AND OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS RELATED TO THE USE OF REFRIGERANTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Customer Safety Information > Page 8667 Refrigerant: Vehicle Damage Warnings CAUTION: To avoid damaging the vehicle or A/C components, the following precautions must be observed. The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging. Failure to due so can contaminate the shop bulk refrigerant and other vehicles. - Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These two types of refrigerant must never be mixed. Doing so can damage the A/C system. - Charge the A/C system with the engine running only at the low-pressure side to prevent refrigerant slugging from damaging the A/C compressor. - Use only R-134a refrigerant. Due to environmental concerns, when the air conditioning system is drained, the refrigerant must be collected using refrigerant recovery/recycling equipment. Federal law REQUIRES that R-134a be recovered into appropriate recovery equipment and the process be conducted by qualified technicians who have been certified by an approved organization, such as MACS, ASI, etc. Use of a recovery machine dedicated to R-134a is necessary to reduce the possibility of oil and refrigerant incompatibility concerns. Refer to the instructions provided by the equipment manufacturer when removing refrigerant from or charging the air conditioning system. - Refrigerant R-134a must not be mixed with air for leak testing or used with air for any other purpose above atmospheric pressure. R-134a is combustible When mixed with high concentrations of air and higher pressures. - A number of manufacturers are producing refrigerant products that are described as direct substitutes for Refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely damage the A/C components. If repair is required, use only new or recycled Refrigerant R-134a. - Use a back-up wrench to prevent damage to the tubes. To avoid contamination of the A/C system: Never open or loosen a connection recovering the refrigerant using approved equipment. - When loosening a connection, if any residual pressure is evident, allow it to leak out before opening the fitting. - Perform the Refrigerant Discharging and Recovery Procedure on a system that has been opened to install a new component or one that has discharged through leakage before charging. - Seal open fittings with a cap or plug immediately after disconnecting a component from the system. - Clean the outside of the fittings thoroughly before disconnecting a component from the system. - Do not remove the sealing caps from a new component until ready to install. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil container until ready to use, and install the cap immediately after using. Store the oil in a clean, moisture-free container. - Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal with refrigerant oil before connecting. - When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or any sharp edges that can chafe the line. - Tighten threaded fittings only to specifications. The steel and aluminum fittings used in the refrigerant system will not tolerate overtightening. - When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the refrigerant lines or tubes. - Do not open a refrigerant system or uncap a new component unless it is as close as possible to room temperature. This will prevent condensation from forming inside a component that is cooler than the surrounding air. - Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. - During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. - If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12 recovery/recycling equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure Special Tool(s) SPECIAL TOOL(S) NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. Refrigerant System Recovery 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. 2. Connect an R-134a A/C service center to the low- and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. 3. Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level on the gauge. If the vacuum does not decrease, disconnect the refrigerant center hose(s). 6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8670 Refrigerant: Service and Repair Identifying Refrigerants Delux A/C Refrigerant Analyzer SPECIAL TOOL(S) 1. Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the sample for testing. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. 2. The diagnostic tool will display one of the following: - If the purity level of R-134a or R-12 is 98% or greater by weight, the green "PASS" light emitting diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will be displayed on the digital display. - If refrigerants R-134a or R-12 do not meet the 98% purity levels, the red "FAIL" LED will light and a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light, "Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22,and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or greater. The diagnostic tool eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the diagnostic tool has determined that a refrigerant source is pure (R-134a or R-12 is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. 5. Perform the Refrigerant Discharging and Recovery Procedure to remove any contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12 recovery/recycling equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8671 Refrigerant: Service and Repair Handling of Contaminated Refrigerants 1. Perform the Refrigerant Discharging and Recovery Procedure to remove the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. - If this equipment is not available, contact an A/C repair facility in your area with the correct equipment to carry out this repair. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. 2. Determine and correct the cause of the customer's initial concern. 3. The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed. Remove the suction accumulator/drier. NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured for correct oil system matching. See: Refrigerant Oil Addition. 4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8. Dispose of contaminated refrigerant according to all federal, state and local regulations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8672 Refrigerant: Service and Repair Evacuation and Charging Special Tool(s) SPECIAL TOOL(S) NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. Refrigerant System Evacuation 1. Connect an R-134a service center to the low- and high-pressure service gauge port valves. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service the leak, and evacuate the system again. Refrigerant System Charging 1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. See: Refrigerant Oil Addition. 2. Charge the system with the specified amounts of refrigerant oil and refrigerant. 3. When no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation. Adjust the blower motor speed to the maximum and allow the remaining refrigerant to be drawn into the system. Continue to add refrigerant into the system until the specified weight of R-134a has been added. Close the charging cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8673 Refrigerant: Service and Repair Leak Detection Electronic Leak Detection Refrigerent Leak Detector SPECIAL TOOL(S) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. 1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 2. If a leak is found, Perform the Refrigerant Discharging and Recovery Procedure to remove the refrigerant. - Repair the system. - Test the system for normal operation. Tracer Dye Leak Detection Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8674 120 Watt 110 Volt UV Lamp 20 Degree Celsius SPECIAL TOOL(S) NOTE: Ford Motor Company vehicles are produced with a permanent leak tracer dye incorporated into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak can exist, always inspect each component. 1. Check for leaks using a 120 Watt UV spot lamp. - Scan all components, fittings and lines of the A/C system. 2. After the leak is repaired, remove any traces of tracer dye with a general purpose oil solvent. 3. Verify the repair by operating the system for a short time and inspect with the UV spot lamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Capacity ............................................................................................................................................... ............................................................ 266 ml (9 oz) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8679 Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil R-134a Systems ................................................................................................................... F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8680 Refrigerant Oil: Service Precautions CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8681 Refrigerant Oil: Service and Repair CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. - Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8682 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice - installation of a new A/C compressor pressure relief valve - installation of a new refrigerant line - repair of an O-ring seal leak - repair of a charge port leak 6. Installation of new components that do not require you to Perform the Refrigerant Discharging and Recovery Procedure of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8686 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Pressure Switch A/C High Pressure Switch Connector Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Pressure Switch > Page 8689 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops, The contacts close when the suction pressure rises. Refer to specifications regarding operating pressure(s). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of air flow. - It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the A/C cycling switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8692 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch PCM Inputs AIR CONDITIONING CYCLING SWITCH The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See: Powertrain Management/Description and Operation/PCM Outputs NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - Standard Corporate Protocol (SCP) communication. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8693 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure Switch The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on the Schrader valve stem. - This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises, the switch contacts open, disengaging the A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C compressor. Refer to specifications regarding operating pressure(s). - It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the A/C pressure cutoff switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Diagram 700-01-00-2 Diagram 700-01-00-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8698 Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8699 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay > Page 8702 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Page 8703 Blower Motor Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Page 8704 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8708 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8709 Compressor Clutch Relay: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8710 Compressor Clutch Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8711 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips Control Module HVAC: Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 8716 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 8717 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams Blower Motor Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 8725 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 8726 Blower Motor Switch: Description and Operation Function Selector Switch The function selector switch combines a vacuum selector valve with two electrical switches to supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit. Temperature Control Switch Temperature selection is accomplished with a potentiometer connected to the electric blend door. Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a corresponding movement on the air temperature that the air system will maintain. Blower Motor Switch The blower motor switch controls blower motor speed by adding or by passing resistors in the heater blower motor switch resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 8727 Blower Motor Switch: Service and Repair CLIMATE CONTROL ASSEMBLY-FRONT SWITCHES REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Manual A/C Electrical Components, Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8731 Manual A/C Electrical Components, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Pressure Switch A/C High Pressure Switch Connector Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Pressure Switch > Page 8734 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops, The contacts close when the suction pressure rises. Refer to specifications regarding operating pressure(s). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of air flow. - It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the A/C cycling switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8737 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch PCM Inputs AIR CONDITIONING CYCLING SWITCH The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See: Powertrain Management/Description and Operation/PCM Outputs NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - Standard Corporate Protocol (SCP) communication. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8738 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure Switch The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on the Schrader valve stem. - This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises, the switch contacts open, disengaging the A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C compressor. Refer to specifications regarding operating pressure(s). - It is not necessary to Perform the Refrigerant Discharging and Recovery Procedure to remove the A/C pressure cutoff switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Refrigerant System Components Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8742 Service Port HVAC: Description and Operation Service Gauge Port Valve The high-pressure service gauge port valve is located on the front A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high-side and low-side service gauge ports. - A new Schrader-type valve core can be installed if the seal leaks. - Always install the A/C charging valve cap on the service gauge port valves after repairing the refrigerant system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information Vacuum Harness HVAC: Customer Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information > Page 8747 Vacuum Harness HVAC: Technician Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 8748 Vacuum Harness HVAC: Service and Repair Vacuum Pump Kit SPECIAL TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch longer than the damaged area of the mini-tube vacuum hose). 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT POSSIBLE PERSONAL INJURY . 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8 inch repair vacuum hose section. 6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the Vacuum Tester or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 8749 Vacuum Pump Kit Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for vacuum reservoir removal. 1 Disconnect the battery ground cable. 2 Remove the air cleaner assembly. 2. Remove the screws. Position the air cleaner housing mounting bracket out of the way. 3. Raise and support the vehicle. 4. Remove the screws. 5. Lower the vehicle. 6. Label and disconnect the vacuum hoses. Remove the vacuum reservoir. NOTE: The vacuum hoses to the vacuum reservoir are not interchangeable. Note the location of each vacuum hose to make sure of correct installation. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment INSPECTION AND REPAIR AFTER A SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPLOYMENT WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When any deployable device or combination of devices are deployed and/or the RCM has the DTC B1231 (Crash Data Memory Full) in memory, the repair of the vehicle's supplemental restraint system (SRS) is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. 2. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 3. When the driver air bag module has deployed, a new clockspring must be installed. 4. Inspect the entire vehicle for damage, including the following components: - Steering column - Instrument panel knee bolsters and mounting points - Instrument panel braces and brackets - Instrument panel and mounting points - Seats and seat mounting points - Safety belts, safety belt buckles and safety belt retractors - Supplemental restraint system (SRS) wiring, wiring harnesses and connectors 5. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 8758 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters, child safety seat tether attachments (if equipped), and attaching hardware should be inspected after any collision. New belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or incorrect operation is noted. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor connector. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side floor connector. 11. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8764 STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector beneath the front seat. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag electrical connector beneath the front seat. 11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat. 12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side air bag electrical connector beneath the front seat. 13. Reconnect the battery ground cable. Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8765 NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8766 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8767 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8768 Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8769 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8770 Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8771 14. Install the two screws. 15. Close the glove compartment door. 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8772 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Procedures For Repair Operations Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8773 accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: . 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8774 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8775 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8776 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8777 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic tool from the driver seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8778 8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. Prove out the system. Seats Not Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the front passenger seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the driver seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver seat. 10. Reconnect the battery ground cable. 11. Prove out the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8779 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8780 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Technician Safety Information Air Bag Harness: Technician Safety Information WARNING: ^ THIS TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED. NEW TRIM COVERS MUST BE INSTALLED (CLEANING IS PERMISSIBLE). ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Technician Safety Information > Page 8786 Air Bag Harness: Vehicle Damage Warnings CAUTION: ^ Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. ^ When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. ^ Use care when connecting the seat cushion side shield to the seat cushion frame so the tabs on the seat cushion side shield are not damaged. ^ Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). If a resistance system diagnostic tool installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. ^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. ^ The retaining nuts of the side air bag module must be tightened in the sequence described. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal Air Bag Harness: Service and Repair Removal Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8789 removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8790 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. 8. Using the special tool, remove the safety belt buckle support bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8791 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8792 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8793 21. Disconnect the clockspring electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED. NEW TRIM COVERS MUST BE INSTALLED (CLEANING IS PERMISSIBLE). 26. Disconnect the seat motor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8794 27. Remove the four bolts and the seat track from the seat bottom. 28. Disconnect the power seat switch electrical connector. 29. Turn the manual lumbar handle clockwise until it stops, releasing all tension on the manual lumbar support cable. 30. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim panel retaining screw. 31. Remove the lower seat trim panel screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8795 32. Remove the lower seat trim panel. 1 Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel from the seat bottom frame. 2 Remove the lower seat trim panel. 33. Remove the push pin holder from the seat bottom frame for the lumbar support cable. NOTE: Install a new pin-type retainer, if damaged. 34. Separate the lumbar support cable assembly. 1 Separate the lumbar support case assembly by sliding apart. 2 Remove the cable end ball from the cable end retainer and separate. 35. Separate the side air bag electrical connector and wire harness from the seat bottom frame. 1 Release the finger clip and slide the side air bag electrical connector from the bracket. 2 Separate the side air bag wire harness pin-type retainer from the seat bottom frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8796 NOTE: Install new pin-type retainers, if damaged. 36. Remove the bolts. 37. Laying the seat on its other side, remove the retaining bolt from the seat pivot. CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 38. Remove the seatback from the seat bottom. 1 While noting the routing, pull the lumbar support cable through the seat bottom. 2 While noting the routing, pull the side air bag module wire harness through the seat bottom. 3 Remove the seat back from the seat bottom. 39. Separate the seat back trim cover lower J-clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8797 40. Remove and discard the hog rings from the two swing rods (one shown). 41. Slide the swing rods out of the seat back trim cover. 42. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 43. Remove and discard the tie-strap holding the deployment chute tail and side air bag wire harness in place. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8798 44. Unzip the side air bag deployment chute. 45. Roll the seat back cover and side air bag deployment chute to completely expose the side air bag module, mounting bracket and side air bag shield. 46. Remove and discard the duct tape retaining the side air bag shield. 47. Separate the side air bag wiring harness pin-type retainers from the seat back frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8799 48. Remove the side air bag stud covers. 49. Remove the side air bag module nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. 50. Position the side air bag module and shield out through the seat back cushion opening. 51. Remove the side air bag module. 1 Slide the side air bag module electrical connector locking clip to disengage it. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8800 52. Remove the shield from the side air bag module. 53. Remove the side air bag wire harness from the seat backrest frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8801 Air Bag Harness: Service and Repair Installation INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the side air bag wire harness to the seat backrest frame. 2. Install the shield onto the side air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8802 3. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 4. Make sure the electrical connector is securely fastened to the side air bag module. 5. Position the side air bag module and shield into the seat backrest cushion. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED AS A UNIT. 6. Position the side air bag module studs, with the shield still in place, through the scat backrest mounting bracket holes. ^ Do not pinch the side air bag module wiring harness between the side air bag module and the mounting bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8803 CAUTION: Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 7. Route the side air bag module wire harness and install the side air bag nuts and tighten in the sequence shown. 1 Route the side air bag module wire harness to the back side of the side air bag mounting bracket making sure it is not pinched between the side air bag module and the mounting bracket. 2 Install the side air bag nut. 3 Install the side air bag nut. 4 Install the side air bag nut. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 8. Install the side air bag stud covers. 9. Position the side air bag shield to the seat backrest frame. 1 Apply new duct tape to the side air bag shield. 2 Position the side air bag module wire harness so that it will fit loosely between the side air bag shield and the mounting bracket. 3 Position the side air bag shield to the seat backrest frame keeping it in place with the tape. ^ Check that the side air bag module wire harness fits loosely between the side air bag shield and the mounting bracket and is not pinched. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8804 10. Route the side air bag wire harness and install the pin-type retainers to the seat back frame. 11. Unroll the seat back trim cover to position the deployment chute around the side air bag module. 12. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED AS A UNIT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8805 ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 13. Zip the air bag deployment chute completely closed, then position the zipper tail at the top of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: Be sure the side air bag deployment chute is properly positioned, before proceeding. 14. Position the deployment chute tail and side air bag wire harness and tie-strap them in place. 15. Unroll the seat back trim cover to the bottom row of hog rings. 16. Install the swing rods back into the seat back trim cover sleeves. 17. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog rings, position the top of the swing rods under the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8806 listing wire in the seat back pad. NOTE: The seat back trim cover has been inverted for clarity. 18. Install new hog rings onto the swing rods (one shown). 19. Pull the seat backrest trim cover completely down and connect the hook and loop fastener to the seat back cushion. 20. Reattach the seat back trim cover lower J-clips. 21. Position the seat back to the seat bottom and route the wires and cables. 1 Position the seat back to the seat bottom. 2 Pull the side air bag module wire harness through the seat bottom. 3 Pull the lumbar support cable through the seat bottom. 22. Align the seat back to the seat bottom. Install the bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8807 CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 23. Install the bolts. CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 24. Route the side air bag module wire harness. 1 Slide the side air bag wire harness onto the finger clip. 2 Install the side air bag wire harness pin-type retainer into the seat bottom frame. 25. Connect the lumbar support cable assembly. 1 Install the cable end ball to the cable end retainer. 2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8808 26. Install the push pin holder to the seat bottom frame and insert the lumbar support cable. 27. Install the seat bottom lower side shield into the seat bottom frame. 1 Align the seat bottom lower side shield retaining clips to the seat bottom. 2 Push in on the lower side shield, seating the clips (one shown) into the seat bottom frame. 28. Install the lower side shield screw. 29. Install the lower side shield retaining screw and the lumbar support handle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8809 30. Connect the power seat switch electrical connector. 31. Position the seat track to the seat bottom frame. Install the four bolts and tighten to specification. 32. Connect the seat motor electrical connector. 33. Position the driver seat into the vehicle. Install and hand-tighten the four seat track to floor bolts. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 34. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8810 35. Connect the driver seat side air bag and power seat electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. 3 Tie-strap the wire harness. 36. Connect the battery ground cable. 37. Position the driver seat rearward. 38. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 39. Tighten the driver seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 40. Move and tilt the driver seat to its highest and most forward position. 41. Tighten the driver seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8811 42. Install the driver seat rear track bolt covers. 43. Connect the safety belt warning indicator electrical connector. 44. Using the special tool, install the safety belt buckle support bolt. 45. Install the safety belt buckle support bolt cover. 46. Position the driver seat rearward. 47. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8812 PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 48. Position the passenger seat forward. 49. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 50. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 51. Position the passenger seat rearward. 52. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 53. Install the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8813 54. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 55. Connect the clockspring electrical connector at the base of the steering column. 56. Position the lower steering column opening finish panel reinforcement and install the bolts. 57. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service and Repair > Removal > Page 8814 58. Position the hood release handle and install the screws. 59. Connect the battery ground cable. 60. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 61. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8819 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8820 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8821 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8822 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8823 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8824 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8825 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8826 Air Bag Control Module: Specifications Restraints Control Module Bolts 12 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8827 Air Bag Control Module: Locations Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8828 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8829 Air Bag Control Module: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8830 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 8833 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 8834 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag supplemental restraint system (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 8835 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module Air Bag Control Module: Service and Repair Restraints Control Module With Side Air Bags SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8838 ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8839 4. Remove the retaining bolts and remove the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8840 SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8841 15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. Reconnect the battery ground cable. 19. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 21. Remove the full floor console. Vehicles with a restraint control module cover 22. Remove the mat, the screws and the Restraint Control Module (RCM) cover. 23. Remove the right-hand side RCM retaining bolts Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8842 24. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8843 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. 6. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8844 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover 8. Position the RCM cover. Install the screws and the mat. 9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8845 11. Position the lower steering column opening finish panel reinforcement and install the bolts. 12. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top seating the retaining clips. 2 Install the screws. 13. Position the hood release handle and install the screws. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8846 15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. Move and tilt the front seats to their highest and most forward position. 18. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 19. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 21. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8847 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 23. Connect the battery ground cable. 24. Position the front seats rearward. 25. Connect the battery ground cable. 26. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Without Side Air Bags SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8848 ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8849 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the retaining bolts and remove the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8850 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 12. Remove the full floor console. Vehicles with a restraint control module cover 13. Remove the mat, the screws and the Restraint Control Module (RCM) cover. 14. Remove the right-hand side RCM retaining bolts Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8851 15. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8852 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8853 6. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover 8. Position the RCM cover. Install the screws and the mat. 9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8854 10. Connect the clockspring electrical connector at the base of the steering column. 11. Position the lower steering column opening finish panel reinforcement and install the bolts. 12. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top seating the retaining clips. 2 Install the screws. 13. Position the hood release handle and install the screws. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8855 VEHICLE SAFETY STANDARDS. 15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8856 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 8857 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Page 8858 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service Precautions Air Bag Resistor: Service Precautions WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service and Repair > Driver Side Air Bag Resistor: Service and Repair Driver Side REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Move and tilt the driver seat to its highest and most forward position. 2. Disconnect the battery ground cable and wait atleast one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Disconnect the driver seat side air bag delete resistor electrical connector. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag delete resistor electrical connector. 4. Remove the driver seat side air bag delete resistor. 1 Push up to release the finger clip. 2 Slide the driver seat side air bag delete resistor off the finger clip. INSTALLATION WARNING: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service and Repair > Driver Side > Page 8864 ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Slide the driver seat side air bag delete resistor onto the finger clip. 2. Connect the driver seat side air bag delete resistor. 1 Connect the driver seat side air bag delete resistor. 2 Tie-strap the wire harness in place. 3. Connect the battery ground cable. 4. Prove out the air bag system. See: Air Bag(s) Arming and Disarming Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service and Repair > Driver Side > Page 8865 Air Bag Resistor: Service and Repair Passenger Side REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Move the passenger seat to its most forward position. 3. Disconnect the passenger seat side air bag delete resistor electrical connector. 1 Remove the tie-strap. 2 Disconnect the passenger seat side air bag delete resistor electrical connector. 4. Remove the passenger seat side air bag delete resistor. 1 Push up to release the finger clip. 2 Slide the passenger seat side air bag delete resistor off the finger clip. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service and Repair > Driver Side > Page 8866 WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Slide the passenger seat side air bag delete resistor onto the finger clip. 2. Connect the passenger seat side air bag delete resistor. 1 Connect the passenger seat side air bag delete resistor. 2 Tie-strap the wire harness in place. 3. Connect the battery ground cable. 4. Prove out the air bag system. See: Air Bag(s) Arming and Disarming Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications Clockspring Assembly / Spiral Cable: Specifications Lower Steering Column Opening Finish Panel Reinforcement Bolts .......................................................................................................... 12 N.m (9 Lb-Ft) Lower Steering Column Opening Finish Panel Screws .............................................................................................................................. 3 N.m (27 Lb-In) Hood Release Handle Screws ............................................................................................................. ......................................................... 3 N.m (27 Lb-In) Steering Column Fore And Aft Nuts ......................................................................................................................................................... 15 N.m (11 Lb-Ft) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8870 Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8871 Clockspring Assembly / Spiral Cable: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Technician Safety Information Clockspring Assembly / Spiral Cable: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ INCORRECT CENTRALIZATION MAY RESULT IN PREMATURE COMPONENT FAILURE. IF IN DOUBT WHEN CENTRALIZING THE CLOCKSPRING, REPEAT THE CENTRALIZING PROCEDURE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 8874 Clockspring Assembly / Spiral Cable: Vehicle Damage Warnings CAUTION: ^ Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. ^ Make sure the road wheels are in the straight-ahead position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 8875 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring: ^ is mounted on the steering column, behind the steering wheel. ^ provides a continuous electrical path between the Restraints Control Module (RCM) and the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags Clockspring Assembly / Spiral Cable: Service and Repair With Side Air Bags SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8878 procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8879 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the base of the steering column. 7. Remove the passenger air bag module. 8. Attach the restraint system diagnostic to the vehicle harness side of the passenger air bag electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8880 12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. Connect the battery ground cable. 19. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8881 SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 21. Remove the two steering wheel back cover plugs. 22. Remove the two driver air bag module retaining bolts. 23. Remove the driver air bag module. 1 Disconnect the driver air bag module electrical connector. 2 Remove the driver air bag module. 24. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8882 25. Loosen, but do not remove, the four steering column-to-instrument panel retaining bolts enough to remove the upper steering column shroud (two shown). Vehicles with tilt column 26. Remove the tilt wheel handle shank. 27. Remove the lower steering column shroud. 1 Remove the three screws. 2 Remove the lower steering column shroud. 28. Remove the ignition switch lock cylinder. 1 Position the ignition switch lock cylinder to the RUN position. 2 Using the suitable tool, push upward on the cylinder release tab while pulling the ignition switch lock cylinder outward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8883 29. Remove the upper steering column shroud. 30. Remove the Passive Anti-theft System (PATS) transmitter. 1 Remove the PATS transmitter retaining screw. 2 Position the PATS transmitter out of the way. 31. Remove the key-in-ignition warning indicator switch. 32. Disconnect the clockspring electrical connectors. 1 Remove the bolt and separate the ground wire. 2 Remove the clockspring electrical connectors from the instrument panel and disconnect the remaining clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8884 33. Remove the clockspring wire harness from the two holders. 34. Release the lower clockspring retaining clip. 35. Remove the clockspring. 1 Release the remaining two clockspring retaining clips. 2 Remove the clockspring. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8885 WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Vehicles receiving a new clockspring 1. Remove the key from the clockspring, holding then rotor in its centralized position. ^ Do not allow the clockspring rotor to turn. NOTE: A new clockspring is supplied in a centralized position and held there with a key. Vehicles needing clockspring recentering 2. Centralize the clockspring. 1 Hold the clockspring outer housing stationary. 2 Depress the clockspring locking tab to release the rotor. 3 While holding the clockspring locking tab into the released position, turn the rotor counterclockwise, carefully feeling for the ribbon wire to run out of length, and a slight resistance is felt. Stop turning at this point. CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. 4 While holding the clockspring locking tab in the released position, turn the rotor clockwise approximately 3 turns. This is the center point of Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8886 the clockspring. ^ Release the clockspring locking tab. Lock the rotor in the centralized position. WARNING: INCORRECT CENTRALIZATION MAY RESULT IN PREMATURE COMPONENT FAILURE. IF IN DOUBT WHEN CENTRALIZING THE CLOCKSPRING, REPEAT THE CENTRALIZING PROCEDURE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. CAUTION: Make sure the road wheels are in the straight-ahead position. NOTE: If a clockspring has rotated out of center, follow through with this step. 3. Position the clockspring onto the steering column shaft. 1 Align the clockspring onto the steering column shaft. 2 Slide the clockspring down the steering column shaft and lock the clips into place. 4. Engage the lower clockspring retaining clip into place. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8887 5. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Connect the clockspring electrical connectors. 1 Connect the two clockspring electrical connectors to the vehicle harness and install the electrical connector pin-type retainers to the bracket. 2 Position the ground wire and install the bolt. 7. Route the wire harness into the two holders. 8. Install the key-in-ignition warning indicator switch to the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8888 9. Install the passive anti-theft system (PATS) transmitter. 1 Position the PATS transmitter to the steering column. 2 Install the PATS transmitter retaining screw. 10. Position the upper steering column shroud to the steering column. 11. Install the lower steering column shroud. 1 Position the lower steering column shroud to the steering column and the upper steering column shroud. 2 Install the screws. 12. Tighten the four steering column to instrument panel retaining bolts (two shown). Vehicles with tilt column Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8889 13. If equipped, install the tilt wheel handle and shank. 14. Install the ignition switch lock cylinder. ^ Align and install the ignition switch lock cylinder to the steering column. ^ Position the ignition switch lock cylinder to the off position. 15. Install the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 16. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 17. Connect the battery ground cable. 18. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 19. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8890 20. Position the lower steering column opening finish panel reinforcement and install the bolts. 21. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 22. Position the hood release handle and install the screws. 23. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8891 24. Position the driver air bag module to the steering wheel. 1 Connect the driver air bag module electrical connector. 2 Position the driver air bag module to the steering wheel. 25. Install the two driver air bag module retaining bolts. 26. Install the two steering wheel back cover plugs. 27. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 28. Install the passenger air bag module. 29. Connect the battery ground cable. 30. Move and tilt the front seats to their highest and most forward position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8892 31. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 32. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 33. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 34. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8893 35. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 36. Connect the battery ground cable. 37. Position the front seats rearward. 38. Connect the battery ground cable. 39. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8894 Clockspring Assembly / Spiral Cable: Service and Repair Without Side Air Bags SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8895 procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8896 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the base of the steering column. 7. Remove the passenger air bag module. 8. Attach the restraint system diagnostic to the vehicle harness side of the passenger air bag electrical connector. 9. Connect the battery ground cable. 10. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8897 12. Remove the two steering wheel back cover plugs. 13. Remove the two driver air bag module retaining bolts. 14. Remove the driver air bag module. 1 Disconnect the driver air bag module electrical connector. 2 Remove the driver air bag module. 15. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 16. Loosen, but do not remove, the four steering column-to-instrument panel retaining bolts enough to remove the upper steering column shroud (two shown). Vehicles with tilt column Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8898 17. Remove the tilt wheel handle shank. 18. Remove the lower steering column shroud. 1 Remove the three screws. 2 Remove the lower steering column shroud. 19. Remove the ignition switch lock cylinder. 1 Position the ignition switch lock cylinder to the RUN position. 2 Using the suitable tool, push upward on the cylinder release tab while pulling the ignition switch lock cylinder outward. 20. Remove the upper steering column shroud. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8899 21. Remove the Passive Anti-theft System (PATS) transmitter. 1 Remove the PATS transmitter retaining screw. 2 Position the PATS transmitter out of the way. 22. Remove the key-in-ignition warning indicator switch. 23. Disconnect the clockspring electrical connectors. 1 Remove the bolt and separate the ground wire. 2 Remove the clockspring electrical connectors from the instrument panel and disconnect the remaining clockspring electrical connector. 24. Remove the clockspring wire harness from the two holders. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8900 25. Release the lower clockspring retaining clip. 26. Remove the clockspring. 1 Release the remaining two clockspring retaining clips. 2 Remove the clockspring. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8901 AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Vehicles receiving a new clockspring 1. Remove the key from the clockspring, holding then rotor in its centralized position. ^ Do not allow the clockspring rotor to turn. NOTE: A new clockspring is supplied in a centralized position and held there with a key. Vehicles needing clockspring recentering 2. Centralize the clockspring. 1 Hold the clockspring outer housing stationary. 2 Depress the clockspring locking tab to release the rotor. 3 While holding the clockspring locking tab into the released position, turn the rotor counterclockwise, carefully feeling for the ribbon wire to run out of length, and a slight resistance is felt. Stop turning at this point. CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. 4 While holding the clockspring locking tab in the released position, turn the rotor clockwise approximately 3 turns. This is the center point of the clockspring. ^ Release the clockspring locking tab. Lock the rotor in the centralized position. WARNING: INCORRECT CENTRALIZATION MAY RESULT IN PREMATURE COMPONENT FAILURE. IF IN DOUBT WHEN CENTRALIZING THE CLOCKSPRING, REPEAT THE CENTRALIZING PROCEDURE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. CAUTION: Make sure the road wheels are in the straight-ahead position. NOTE: If a clockspring has rotated out of center, follow through with this step. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8902 3. Position the clockspring onto the steering column shaft. 1 Align the clockspring onto the steering column shaft. 2 Slide the clockspring down the steering column shaft and lock the clips into place. 4. Engage the lower clockspring retaining clip into place. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8903 6. Connect the clockspring electrical connectors. 1 Connect the two clockspring electrical connectors to the vehicle harness and install the electrical connector pin-type retainers to the bracket. 2 Position the ground wire and install the bolt. 7. Route the wire harness into the two holders. 8. Install the key-in-ignition warning indicator switch to the steering column. 9. Install the passive anti-theft system (PATS) transmitter. 1 Position the PATS transmitter to the steering column. 2 Install the PATS transmitter retaining screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8904 10. Position the upper steering column shroud to the steering column. 11. Install the lower steering column shroud. 1 Position the lower steering column shroud to the steering column and the upper steering column shroud. 2 Install the screws. 12. Tighten the four steering column to instrument panel retaining bolts (two shown). Vehicles with tilt column 13. If equipped, install the tilt wheel handle and shank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8905 14. Install the ignition switch lock cylinder. ^ Align and install the ignition switch lock cylinder to the steering column. ^ Position the ignition switch lock cylinder to the off position. 15. Install the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 16. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 17. Connect the battery ground cable. 18. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 19. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 20. Position the lower steering column opening finish panel reinforcement and install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8906 21. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 22. Position the hood release handle and install the screws. 23. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 24. Position the driver air bag module to the steering wheel. 1 Connect the driver air bag module electrical connector. 2 Position the driver air bag module to the steering wheel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > With Side Air Bags > Page 8907 25. Install the two driver air bag module retaining bolts. 26. Install the two steering wheel back cover plugs. 27. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 28. Install the passenger air bag module. 29. Connect the battery ground cable. 30. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Page 8908 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor Bolts 12 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Right Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Right > Page 8914 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 8917 Impact Sensor: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Page 8918 Impact Sensor: Description and Operation WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS contains two sensors which are integral to the RCM. The RCM is mounted on the center tunnel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Side Crash Sensor, Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8921 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8922 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8923 SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8924 15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the diagnostic tools in place at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 19. Position the front seats to their most forward position. 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 21. Pull to release the retaining clips and remove the windshield side garnish molding. 22. Pull up to release the retaining clips and remove the front door scuff plate. 23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8925 24. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26. Position the carpet aside at the front safety belt anchor. 27. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. 28. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8926 3 Remove the quarter trim panel front screw. 29. Fold the rear seat into the load floor position. 30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 31. Remove the retractable cargo cover. All Vehicles 32. Remove the rear safety belt guide. 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. 3 Remove the rear safety belt guide. 33. Position the carpet aside at the rear safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8927 34. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 35. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 36. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. 37. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8928 38. Remove the pin-type retainers from the quarter trim panel. 39. Slide the quarter trim panel forward and disengage it from the door jamb. 40. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8929 42. Position the side crash sensor with bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side crash sensor with bracket away from the B-pillar. 43. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8930 removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Connect the side crash sensor electrical connector. 1 Position the side crash sensor. 2 Connect the side crash sensor electrical connector. 2. Install the side crash sensor. 1 Position the side crash sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest and most forward position. 8. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8931 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 9. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbings through the openings in the quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 10. Slide back and engage the edge of the quarter trim panel into the door jamb. 11. Install the quarter trim panel rear screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8932 12. Through the front door opening, install the quarter trim panel front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim panel front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 13. Install the pin-type retainers into the quarter trim panel. 14. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 15. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Vehicles with a rear power lock switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8933 16. Connect and install the rear power lock switch assembly into the rear quarter trim panel. All vehicles 17. Position the washer on the rear safety belt guide bolt. 18. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 19. Fold the rear seat into the load floor position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8934 20. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 21. Reposition the carpet back over the floor. 22. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo covers 23. Install the retractable cargo cover. All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8935 24. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 25. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 26. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 27. Reposition the carpet at the front safety belt anchor. 28. Align the retaining clips and install the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8936 29. Align the retaining clips and install the windshield side garnish molding. 30. Reposition the rear seat back upward. 31. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 32. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 33. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8937 VEHICLE SAFETY STANDARDS. 34. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 35. Connect the battery ground cable. 36. Position the front seats rearward. 37. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 38. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 39. Install the passenger air bag module. 40. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8938 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 41. Connect the clockspring electrical connector at the base of the steering column. 42. Position the lower steering column opening finish panel reinforcement and install the bolts. 43. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 44. Position the hood release handle and install the screws. 45. Connect the battery ground cable. 46. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8939 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 47. Check the restraint system for correct operation. Side Crash Sensor, Passenger Side Special Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8940 NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All Vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the passenger air bag module. 3. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 4. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8941 5. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 6. Remove the bolts and the lower steering column opening finish panel reinforcement. 7. Disconnect the clockspring electrical connector at the base of the steering column. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8942 DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8943 15. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the diagnostic tools in place at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 19. Position the front seats to their most forward position. 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 21. Pull to release the retaining clips and remove the windshield side garnish molding. 22. Pull up to release the retaining clips and remove the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8944 23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. 24. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26. Position the carpet aside at the front safety belt anchor. 27. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8945 28. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. 3 Remove the quarter trim panel front screw. 29. Fold the rear seat into the load floor position. 30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 31. Remove the retractable cargo cover. All Vehicles 32. Remove the rear safety belt guide. 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8946 3 Remove the rear safety belt guide. 33. Position the carpet aside at the rear safety belt anchor. 34. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 35. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 36. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. 37. Remove the coat hook. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8947 1 Remove the screw. 2 Remove the coat hook. 38. Remove the pin-type retainers from the quarter trim panel. 39. Slide the quarter trim panel forward and disengage it from the door jamb. 40. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8948 42. Position the side crash sensor with the bracket away from the B-pillar. 1. Remove the bolts. 2. Position the side crash sensor with the bracket away from the B-pillar. 43. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM(SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8949 removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Connect the side crash sensor electrical connector. 1 Position the side crash sensor. 2 Connect the side crash sensor electrical connector. 2. Install the side crash sensor. 1 Position the side crash sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest and most forward position. 8. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8950 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS. NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 9. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbing through the openings in the quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 10. Slide back and engage the edge of the quarter trim panel into the door jamb. 11. Install the quarter trim panel rear screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8951 12. Through the front door opening, install the quarter trim panel front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim panel front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 13. Install the pin-type retainers into the quarter trim panel. 14. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 15. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8952 16. Position the washer on the rear safety belt guide bolt. 17. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 18. Fold the rear seat into the load floor position. 19. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 20. Reposition the carpet back over the floor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8953 21. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo covers 22. Install the retractable cargo cover. All Vehicles 23. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 24. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8954 ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 25. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 26. Reposition the carpet at the front safety belt anchor. 27. Align the retaining clips and install the front door scuff plate. 28. Align the retaining clips and install the windshield side garnish molding. 29. Reposition the rear seat back upward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8955 30. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 31. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 32. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 33. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8956 34. Connect the battery ground cable. 35. Position the front seats rearward. 36. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 37. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 38. Connect the clockspring electrical connector at the base of the steering column. 39. Position the lower steering column opening finish panel reinforcement and install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8957 40. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 41. Position the hood release handle and install the screws. 42. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 43. Install the passenger air bag module. 44. Connect the battery ground cable. 45. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 46. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8958 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8959 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Page 8960 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safing sensor is internal to the RCM and is not serviced separately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information Side Air Bag: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE. SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH A SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 8968 Side Air Bag: Vehicle Damage Warnings CAUTION: ^ Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. ^ When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8969 Side Air Bag: Description and Operation Driver Side Air bag Module NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the Supplemental Restraint System (SRS). The driver side air bag module: ^ has no separately repairable parts and is installed as an assembly. ^ is mounted in the driver seat back. Passenger Side Air Bag Module NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the supplemental restraint system (SRS). The passenger side air bag module: ^ has no separately repairable parts and is installed as an assembly. ^ is mounted in the passenger seat back. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Side Air Bag: Service and Repair Driver Side Removal Special Tool(s) SPECIAL TOOL(S) WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE. SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8972 vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ When replacing the side air bag after deployment. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8973 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support assembly. 8. Using the special tool, remove the safety belt buckle support assembly bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8974 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8975 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8976 21. Disconnect the clockspring electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 25. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 26. Disconnect the seat motor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8977 27. Remove the four bolts and the seat track from the seat bottom. 28. Disconnect the power seat switch electrical connector. 29. Turn the manual lumbar handle clockwise until it stops, releasing all tension on the manual lumbar support cable. 30. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim panel retaining screw. 31. Remove the lower seat trim panel screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8978 32. Remove the lower seat trim panel. 1 Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel from the seat bottom frame. 2 Remove the lower seat trim panel. 33. Remove the push pin holder from the seat bottom frame for the lumbar support cable. NOTE: Install a new pin-type retainer if damaged. 34. Separate the lumbar support cable assembly. 1 Separate the lumbar support case assembly by sliding apart. 2 Remove the cable end ball from the cable end retainer and separate. 35. Separate the side air bag electrical connector and wire harness from the seat bottom frame. 1 Release the finger clip and slide the side air bag electrical connector off the bracket. 2 Separate the side air bag wire harness pin-type retainer from the seat bottom frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8979 NOTE: Install new pin-type retainers if damaged. 36. Remove the two bolts. 37. Laying the seat on its other side, remove the retaining bolt for the seat pivot. CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 38. Remove the seat back from the seat bottom. 1 Note the routing, and pull the lumbar support cable through the seat bottom. 2 Note the routing, and pull the side air bag module wire harness through the seat bottom. 3 Remove the seat back from the seat bottom. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH A SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8980 39. Separate the seat back trim cover lower J-clip. 40. Remove and discard the hog rings from the two swing rods (one shown). 41. Slide the swing rods out of the seat back trim cover. 42. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8981 43. Remove and discard the tie-strap holding the deployment chute tail and side air bag wire harness in place. 44. Unzip the side air bag deployment chute. 45. Roll the seat back cover and side air bag deployment chute to completely expose the side air bag module, mounting bracket and side air bag shield. 46. Remove and discard the duct tape retaining the side air bag shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8982 47. Separate the side air bag wiring harness pin-type retainers from the seat back frame. 48. Remove the side air bag stud covers. 49. Remove the side air bag module nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. 50. Position the side air bag module and shield out through the seat back cushion opening. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8983 51. Remove the side air bag module. 1 Slide the side air bag module electrical connector locking clip to disengage it. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 52. Remove the shield from the side air bag module. Installation WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped)system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8984 ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ When replacing the side air bag after deployment. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the shield onto the side air bag module. 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. 4. Position the side air bag module and shield into the seat backrest cushion. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8985 SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. 5. Position the side air bag module studs, with the shield still in place, through the seat backrest mounting bracket holes. ^ Do not pinch the side air bag module wiring harness between the side air bag module and the mounting bracket. CAUTION: Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 6. Route the side air bag module wire harness. Install the side air bag nuts and tighten in the sequence shown. 1 Route the side air bag module wire harness to the back side of the side air bag mounting bracket making sure it is not pinched between the side air bag module and the mounting bracket. 2 Install the side air bag nut. 3 Install the side air bag nut. 4 Install the side air bag nut. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 7. Install the side air bag stud covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8986 8. Position the side air bag shield to the seat backrest frame. 1 Apply new duct tape to the side air bag shield. 2 Position the side air bag module wire harness so that it will fit loosely between the side air bag shield and the mounting bracket. 3 Position the side air bag shield to the seat backrest frame keeping it in place with the tape. ^ Check that the side air bag module wire harness fits loosely between the side air bag shield and the mounting bracket and is not pinched. 9. Route the side air bag wire harness and install the pin-type retainers to the seat back frame. 10. Unroll the seat back trim cover, to position the deployment chute around the side air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8987 11. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 12. Zip the air bag deployment chute completely closed, then position the zipper tail at the top of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: Be sure the side air bag deployment chute is correctly positioned, before proceeding. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8988 13. Position the deployment chute tail and side air bag wire harness and tie-strap them in place. 14. Unroll the seat back trim cover to the bottom row of hog rings. 15. Install the swing rods back into the seat back trim cover sleeves. 16. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog rings, position the top of the swing rods under the listing wire in the seat back pad. NOTE: The seat back trim cover has been inverted for clarity. 17. Install new hog rings onto the swing rods (one shown). 18. Pull the seat back rest trim cover completely down and connect the hook and loop fastener to the seat back cushion. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8989 19. Reattach the seat back trim cover lower J-clips. 20. Position the seat back to the seat bottom and route the wires and cables. 1 Position the seat back to the seat bottom. 2 Pull the side air bag module wire harness through the seat bottom. 3 Pull the lumbar support cable through the seat bottom. 21. Align the seat back to the seat bottom. Install the bolt and tighten to specification. CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to. damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 22. Install the two bolts and tighten to specification. CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8990 23. Route the side air bag module wire harness. 1 Slide the side air bag wire harness onto the finger clip. 2 Install the side air bag wire harness pin-type retainer into the seat bottom frame. 24. Connect the lumbar support cable assembly. 1 Install the cable end ball to the cable end retainer. 2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot. 25. Install the push pin holder to the seat bottom frame and insert the lumbar support cable. 26. Install the seat bottom lower side shield into the seat bottom frame. 1 Align the seat bottom lower side shield retaining clips to the seat bottom. 2 Push in on the lower side shield, seating the clips (one shown) into the seat bottom frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8991 27. Install the lower side shield screw. 28. Install the lower side shield retaining screw and the lumbar support handle. 29. Connect the power seat switch electrical connector. 30. Position the seat track to the seat bottom frame. Install the four bolts and lighten to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8992 31. Connect the seat motor electrical connector. 32. Position the driver seat into the vehicle. Install and hand-tighten the four seat track to floor bolts. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 33. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 34. Connect the driver seat side air bag and power seat electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. 3 Tie-strap the wire harness. 35. Connect the battery ground cable. 36. Position the driver seat rearward. 37. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8993 38. Tighten in sequence the driver seat front track to floor bolts. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 39. Move and tilt the driver seat to its highest and most forward position. 40. Tighten in sequence the driver seat rear track to floor bolts. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. 41. Install the driver seat rear track bolt covers. 42. Connect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8994 43. Using the special tool, install the safety belt buckle support assembly bolt. 44. Install the safety belt buckle support assembly bolt cover. 45. Position the driver seat rearward. 46. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 47. Position the passenger seat forward. 48. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8995 49. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 50. Position the passenger seat rearward. 51. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 52. Install the passenger air bag module. 53. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8996 54. Connect the clockspring electrical connector at the base of the steering column. 55. Position the lower steering column opening finish panel reinforcement and install the bolts. 56. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top seating the retaining clips. 2 Install the screws. 57. Position the hood release handle and install the screws. 58. Connect the battery ground cable. 59. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8997 VEHICLE SAFETY STANDARDS. 60. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8998 Side Air Bag: Service and Repair Passenger Side Removal Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 8999 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat Systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ When replacing the side air bag after deployment. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the passenger seat rearward. 2. Remove the passenger seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9000 6. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 7. Remove the safety belt buckle support assembly bolt cover plug. 8. Using the special tool, remove the safety belt buckle support assembly bolt. 9. Remove the passenger seat rear bolt trim covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9001 10. Remove the passenger seat rear bolts. 11. Remove the passenger seat from the vehicle. CAUTION: Use care when handling the seat and track assembly.Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 14. Connect the battery ground cable. 15. Position the driver seat rearward. 16. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9002 17. Remove the retaining screws and position the hood release handle out of the way. 18. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 19. Remove the bolts and remove the lower steering column opening finish panel reinforcement. 20. Disconnect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9003 21. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 22. Remove the passenger air bag module. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 24. Connect the battery ground cable. 25. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 26. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Driver seat is shown, passenger seat is similar. 27. Remove the four bolts and the seat track from the seat bottom. 28. Turn the manual lumbar handle clockwise until it stops, releasing all tension on the manual lumbar support cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9004 29. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim panel retaining screw. 30. Remove the side shield screw. 31. Remove the lower seat trim panel. 1 Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel from the seat bottom frame. 2 Remove the lower seat trim panel. 32. Remove the push pin holder from the seat bottom frame for the lumbar support cable. NOTE: Install a new pin-type retainer if damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9005 33. Separate the lumbar support cable assembly. 1 Separate the lumbar support case assembly by sliding apart. 2 Remove the cable end ball from the cable end retainer and separate. 34. Separate the side air bag electrical connector and wire harness from the seat bottom frame. 1 Release the finger clip and slide the side air bag electrical connector off the bracket. 2 Separate the side air bag wire harness pin-type retainer form the seat bottom frame. NOTE: Install new pin-type retainers if damaged. 35. Remove the two bolts. 36. Laying the seat on its other side, remove the retaining bolt for the seat pivot. CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9006 37. Remove the seat back from the seat bottom. 1 While noting the routing, pull the lumbar support cable through the seat bottom. 2 While noting the routing, pull the side air bag module wire harness through the seat bottom. 3 Remove the seat back front the seat bottom. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEARING IS PERMISSIBLE). 38. Separate the seat back trim cover lower J-clip. 39. Remove and discard the hog rings from the two swing rods (one shown). 40. Slide the swing rods out of the seat back trim cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9007 41. Roll the seat back trim cover, in an inside-out fashion, to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 42. Remove and discard the tie-strap holding the deployment chute tail and side air bag wire harness in place. 43. Unzip the side air bag deployment chute. 44. Roll the seat back cover and side air bag deployment chute to completely expose the side air bag module, mounting bracket and side air bag shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9008 45. Remove and discard the duct tape retaining the side air bag shield. 46. Separate the side air bag wiring harness pin-type retainers from the seat back frame. 47. Remove the side air bag stud covers. 48. Remove the side air bag module nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9009 49. Position the side air bag module and shield out through the seat back cushion opening. 50. Remove the side air bag module. 1 Slide the side air bag module electrical connector locking clip to disengage it. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 51. Remove the shield from the side air bag module. Installation INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9010 AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ When installing a new side air bag after deployment. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Driver seat is shown, passenger seat is similar. 1. Install the shield onto the side air bag module. 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9011 4. Position the side air bag module and shield into the seat backrest cushion. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. 5. Position the side air bag module studs, with the shield still in place, through the seat backrest mounting bracket holes. ^ Do not pinch the side air bag module wiring harness between the side air bag module and the mounting bracket. CAUTION: Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 6. Route the side air bag module wire harness. Install the side air bag nuts and tighten in the sequence shown. 1 Route the side air bag module wire harness to the back side of the side air bag mounting bracket, making sure it is not pinched between the side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9012 air bag module and the mounting bracket. 2 Install the side air bag nut. 3 Install the side air bag nut. 4 Install the side air bag nut. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 7. Install the side air bag stud covers. 8. Position the side air bag shield to the seat backrest frame. 1 Apply new tape to the side air bag shield. 2 Position the side air bag module wire harness so that it will fit loosely between the side air bag shield and the mounting bracket. 3 Position the side air bag shield to the seat backrest frame keeping it in place with the tape. ^ Check that the side air bag module wire harness fits loosely between the side air bag shield and the mounting bracket and is not pinched. 9. Route the side air bag wire harness and install the pin-type retainers to the seat back frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9013 10. Unroll the seat back trim cover, to position the deployment chute around the side air bag module. 11. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9014 12. Zip the air bag deployment chute completely closed, then position the zipper tail at the top of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: Be sure the side air bag deployment chute is correctly positioned, before proceeding. 13. Position the deployment chute tail and side air bag wire harness and tie-strap them in place. 14. Unroll the seat back trim cover to the bottom row of hog rings. 15. Install the swing rods back into the seat back trim cover sleeves. 16. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog rings, position the top of the swing rods under the listing wire in the seat back pad. NOTE: The seat hack trim cover has been inverted for clarity. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9015 17. Install new hog rings onto the swing rods (one shown). 18. Pull the seat back rest trim cover completely down and connect the hook and loop fastener to the seat back cushion. 19. Reattach the seat back trim cover lower J-clips. 20. Position the seat back to the seat bottom and route the wires and cables. 1 Position the seat back to the seat bottom. 2 Pull the side air bag module wire harness through the seat bottom. 3 Pull the lumbar support cable through the seat bottom. 21. Align the seat back to the seat bottom. Install the bolt and tighten to specification. CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9016 22. Install the two bolts and tighten to specification. CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 23. Route the side air bag module wire harness. 1 Slide the side air bag wire harness onto the finger clip. 2 Install the side air bag wire harness pin-type retainer into the seat bottom frame. 24. Connect the lumbar support cable assembly. 1 Install the cable end ball to the cable end retainer. 2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot. 25. Install the push pin holder to the seat bottom frame and insert the lumbar support cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9017 26. Install the seat bottom lower side shield into the seat bottom frame. 1 Align the seat bottom lower side shield retaining clips to the seat bottom. 2 Push in on the lower side shield, seating the clips (one shown) into the seat bottom frame. 27. Install the lower side shield screw. 28. Install the lower side shield retaining screw and the lumbar support handle. 29. Position the seat track to the seat bottom frame. Install the tour bolts and tighten to specification. 30. Position the passenger seat into the vehicle. Install and hand tighten the four seat track-to-floor bolts CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9018 31. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 32. Connect the passenger seat side air bag electrical connector and tic-strap the wire harness. 33. Connect the battery ground cable. 34. Position the front seats rearward. 35. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 36. Tighten in sequence the passenger seat front track-to-floor bolts. 1 Tighten to specification the front inboard bolt. 2 Tighten to specification the front outboard bolt. 37. Move and tilt the front seats to their highest and most forward position. 38. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL; CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE, BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9019 39. Tighten in sequence the passenger seat rear track-to-floor bolts. 1 Tighten to specification the rear inboard bolt. 2 Tighten to specification the rear outboard bolt. 40. Install the passenger seat rear track bolt covers. 41. Using the special tool, install the safety belt buckle support assembly bolt. 42. Install the safety belt buckle support assembly bolt cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9020 43. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 44. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 45. Connect the battery ground cable. 46. Position the front seats rearward. 47. Disconnect the battery ground cable and wait at least one minute. 48. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9021 49. Connect the clockspring electrical connector at the base of the steering column. 50. Position the lower steering column opening finish panel reinforcement and install the bolts. 51. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the instrument panel. Push in the top of the lower steering column opening finish panel to seat the retaining clips. 2 Install the screws. 52. Position the hood release handle and install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side > Page 9022 53. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 54. Install the passenger air bag module. 55. Connect the battery ground cable. 56. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 57. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Page 9023 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9029 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9030 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9031 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9032 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9033 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9034 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9035 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 9036 Air Bag Control Module: Specifications Restraints Control Module Bolts 12 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 9037 Air Bag Control Module: Locations Air Bag Supplemental Restraint System (SRS) Components - Explorer Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 9038 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 9039 Air Bag Control Module: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 9040 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 9043 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 9044 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag supplemental restraint system (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 9045 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module Air Bag Control Module: Service and Repair Restraints Control Module With Side Air Bags SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9048 ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9049 4. Remove the retaining bolts and remove the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9050 SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9051 15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. Reconnect the battery ground cable. 19. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 21. Remove the full floor console. Vehicles with a restraint control module cover 22. Remove the mat, the screws and the Restraint Control Module (RCM) cover. 23. Remove the right-hand side RCM retaining bolts Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9052 24. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9053 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. 6. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9054 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover 8. Position the RCM cover. Install the screws and the mat. 9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9055 11. Position the lower steering column opening finish panel reinforcement and install the bolts. 12. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top seating the retaining clips. 2 Install the screws. 13. Position the hood release handle and install the screws. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9056 15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. Move and tilt the front seats to their highest and most forward position. 18. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 19. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 21. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9057 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 23. Connect the battery ground cable. 24. Position the front seats rearward. 25. Connect the battery ground cable. 26. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Without Side Air Bags SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9058 ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9059 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the retaining bolts and remove the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9060 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 12. Remove the full floor console. Vehicles with a restraint control module cover 13. Remove the mat, the screws and the Restraint Control Module (RCM) cover. 14. Remove the right-hand side RCM retaining bolts Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9061 15. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats. in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9062 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9063 6. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover 8. Position the RCM cover. Install the screws and the mat. 9. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9064 10. Connect the clockspring electrical connector at the base of the steering column. 11. Position the lower steering column opening finish panel reinforcement and install the bolts. 12. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top seating the retaining clips. 2 Install the screws. 13. Position the hood release handle and install the screws. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9065 VEHICLE SAFETY STANDARDS. 15. Install the passenger air bag module. 16. Connect the battery ground cable. 17. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9066 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module > Page 9067 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Page 9068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9073 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9074 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9075 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9076 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9077 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9078 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9079 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9084 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor connector. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side floor connector. 11. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9090 STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector beneath the front seat. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag electrical connector beneath the front seat. 11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat. 12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side air bag electrical connector beneath the front seat. 13. Reconnect the battery ground cable. Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9091 NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9092 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9093 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9094 Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9095 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9096 Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9097 14. Install the two screws. 15. Close the glove compartment door. 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9098 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Procedures For Repair Operations Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9099 accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9100 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9101 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9102 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9103 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic tool from the driver seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9104 8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. Prove out the system. Seats Not Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the front passenger seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the driver seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver seat. 10. Reconnect the battery ground cable. 11. Prove out the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9105 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9106 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraints - Seat Belt Stop Button Service Seat Belt: Technical Service Bulletins Restraints - Seat Belt Stop Button Service TSB 05-3-10 02/21/05 SAFETY BELT WEB STOP BUTTON SERVICE FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty 2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005 Escape Hybrid LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding down when not in use), a service kit is now available. ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of the appropriate model year Workshop Manual for additional information if needed. NOTE ONE KIT WILL REPAIR ONE SEAT BELT BUTTON. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 70611B09 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Two Door Seat Belt: Specifications Two Door Models Rear Seat Center Occupant Safety Belt Retractor And Passenger Side Safety Belt Buckle Assembly Bolt 40 Nm Safety Belt Retractor Bolts 40 Nm Safety Belt Anchor Bolts 40 Nm Safety Belt Slide Bar-to-Floor Bolt 40 Nm Safety Belt Slide Bar-to-Seat Track Bolt 9 Nm Safety Belt Slide Bar-to-Seat Track Nut 9 Nm Safety Belt Guide Bolt 40 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Two Door > Page 9113 Seat Belt: Specifications Four Door Models Front Safety Belt Retractor Upper Sheet Metal Bolt 7 Nm Safety Belt Anchor Bolts 40 Nm Safety Belt Slide Bar-to-Floor Bolt 40 Nm Safety Belt Slide Bar-to-Seat Track Bolt 9 Nm Safety Belt Slide Bar-to-Seat Track Nut 9 Nm Safety Belt Guide Bolt 40 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Page 9114 Seat Belt: Service Precautions WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERITY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor Seat Belt: Service and Repair Front Safety Belt and Retractor Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. All Vehicles 1. Pull to release the retaining clips and remove the windshield side garnish molding. 2. Pull up to release the retaining clips and remove the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9117 3. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. 4. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 5. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 6. Position the carpet aside at the front safety belt anchor. 7. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9118 8. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. 3 Remove the quarter trim panel front screw. 9. Fold the rear seat into the load floor position. 10. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 11. Remove the retractable cargo cover. All vehicles 12. Remove the rear safety belt guide. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9119 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. 3 Remove the rear safety belt guide. 13. Position the carpet aside at the rear safety belt anchor. 14. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 15. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 16. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9120 17. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. Vehicles with a rear power lock switch 18. Through the jack access panel, release the rear power lock switch assembly retaining tab and pull the switch through. 19. Disconnect and remove the rear power lock switch assembly. All Vehicles 20. Remove the pin-type retainers from the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9121 21. Slide the quarter trim panel forward and disengage it from the door jamb. 22. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 23. Remove the safety belt web guide. 1 Remove the bolt. 2 Remove the safety belt web guide from the B-pillar. 24. Remove the front safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the front safety belt retractor. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9122 WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. All Vehicles 1. Install the front safety belt retractor. 1 Position the front safety belt retractor to the B-pillar. 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the safety belt web guide. 1 Position the safety belt web guide to the B-pillar. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 3. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbings through the openings in the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9123 NOTE: Make sure the safety belt webbing is not twisted prior to installation. 4. Slide back and engage the edge of the quarter trim panel into the doorjamb. 5. Install the quarter trim panel rear screws. 6. Through the front door opening, install the quarter trim front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 7. Install the pin-type retainers into the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9124 8. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 9. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Vehicles with a rear power lock switch 10. Connect and install the rear power lock switch assembly into the rear quarter trim panel. All Vehicles 11. Position the washer on the rear safety belt guide bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9125 12. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 13. Fold the rear seat into the load floor position. 14. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 15. Reposition the carpet back over the floor. 16. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo cover Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9126 17. Install the retractable cargo cover. All Vehicles 18. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 19. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9127 20. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 21. Reposition the carpet at the front safety belt anchor. 22. Align the retaining clips and install the front door scuff plate. 23. Align the retaining clips and install the windshield side garnish molding. 24. Reposition the rear seat back up. 25. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9128 Seat Belt: Service and Repair Rear Safety Belt and Retractor Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. All Vehicles 1. Pull to release the retaining clips and remove the windshield side garnish molding. 2. Pull up to release the retaining clips and remove the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9129 3. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. 4. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 5. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 6. Position the carpet aside at the front safety belt anchor. 7. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9130 8. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. 3 Remove the quarter trim panel front screw. 9. Fold the rear seat into the load floor position. 10. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 11. Remove the retractable cargo cover. All Vehicles 12. Remove the rear safety belt guide. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9131 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. 3 Remove the rear safety belt guide. 13. Position the carpet aside at the rear safety belt anchor. 14. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 15. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 16. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9132 17. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. Vehicles with rear power lock switch 18. Through the jack access panel, release the rear power lock switch assembly retaining tab and pull the switch through. 19. Disconnect and remove the rear power lock switch assembly. All Vehicles 20. Remove the pin-type retainers from the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9133 21. Slide the quarter trim panel forward and disengage it from the doorjamb. 22. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 23. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. All Vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9134 1. Install the rear safety belt retractor. 1 Position the rear safety belt retractor to the B-pillar. 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbings through the openings in the quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 3. Slide back and engage the edge of the quarter trim panel into the door jamb. 4. Install the quarter trim panel rear screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9135 5. Through the front door opening, install the quarter trim panel front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim panel front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 6. Install the pin-type retainers into the quarter trim panel. 7. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 8. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9136 Vehicles with rear power lock switch 9. Connect and install the rear power lock switch assembly into the rear quarter trim panel. All Vehicles 10. Position the washer on the rear safety belt guide bolt. 11. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 12. Fold the rear seat into the load floor position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9137 13. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 14. Reposition the carpet back over the floor. 15. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo covers 16. Install the retractable cargo cover. All Vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9138 17. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 18. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 19. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 20. Reposition the carpet at the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Safety Belt and Retractor > Page 9139 21. Align the retaining clips and install the front door scuff plate. 22. Align the retaining clips and install the windshield side garnish molding. 23. Reposition the rear seat back up. 24. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 9140 Seat Belt Bolt Bit (Used For T-50 Head Bolt) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications Seat Belt Buckle: Specifications Front Safety Belt Buckle-To-Slide Bar Bolt 40 Nm Rear Seat Center Occupant Safety Belt Retractor And Passenger Side Safety Belt Buckle Assembly Bolt 40 Nm Rear Seat Safety Belt Buckle Assembly Front Nuts 40 Nm Rear Seat Safety Belt Buckle Assembly Rear Nuts 48 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service Precautions > Technician Safety Information Seat Belt Buckle: Technician Safety Information WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE THE RESTRAINT SYSTEM DIAGNOSTIC TOOL FROM THE PASSENGER SEAT SIDE AIR BAG FLOOR ELECTRICAL CONNECTOR. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service Precautions > Technician Safety Information > Page 9146 Seat Belt Buckle: Vehicle Damage Warnings CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag Seat Belt Buckle: Service and Repair Front Seats Without Side Air Bag Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side is shown, passenger side is similar. 1. Remove the front driver or passenger seat from the vehicle. 2. Remove the safety belt buckle support assembly. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support assembly. 3. Remove the safety belt buckle. 1 Clamp the safety belt buckle support assembly in a suitable vise. 2 Using the special tool, remove the safety belt buckle bolt. 3 Remove the safety belt buckle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9149 NOTE: Clamp the safety belt buckle support assembly collar in a vise along the break line only. INSTALLATION WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Install the safety belt buckle onto the safety belt buckle support assembly. 1 Position the safety belt buckle onto the safety belt buckle support assembly. 2 Using the special tool, install the safety belt buckle bolt. 3 Remove the safety belt buckle support assembly from the vise. 2. Install the safety belt buckle support assembly onto the seat. 1 Position the safety belt buckle support assembly to the seat. 2 Install the nut and bolt. 3. Install the front driver or passenger seat into the vehicle. 4. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9150 Seat Belt Buckle: Service and Repair Driver Seat With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND INSTALL NEW IF EITHER DAMAGE OR INCORRECT OPERATION IS NOTED. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9151 ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9152 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support assembly bolt cover plug. 8. Using the special tool, remove the safety belt buckle support assembly bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9153 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. 13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9154 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9155 21. Disconnect the air bag sliding contact electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the air bag sliding contact electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 25. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 26. Remove the safety belt buckle support assembly. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9156 27. Remove the safety belt buckle. 1 Clamp the safety belt buckle support assembly in a suitable vise. 2 Using the special tool, remove the safety belt buckle bolt. 3 Remove the safety belt buckle. NOTE: Clamp the safety belt buckle support assembly collar in a vise along the break line only. INSTALLATION WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced, the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9157 1. Install the safety belt buckle onto the safety belt buckle support assembly. 1 Position the safety belt buckle onto the slide bar. 2 Using the special tool, install the safety belt buckle bolt. 3 Remove the safety belt buckle support assembly from the vise. 2. Install the safety belt buckle support assembly onto the seat. 1 Position the safety belt buckle support assembly to the seat. 2 Install the nut and bolt. 3. Position the driver seat into the vehicle. Install and hand tighten the four seat track-to-floor bolts. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9158 5. Connect the driver seat side air bag and power seat electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. 3 Tie-strap the wire harness. 6. Connect the battery ground cable. 7. Position the driver seat rearward. 8. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 9. Tighten in sequence the driver seat front track-to-floor bolts. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 10. Move and tilt the driver seat to its highest and most forward position. 11. Tighten in sequence the driver seat rear track-to-floor bolts. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9159 12. Install the driver seat rear track bolt covers. 13. Connect the safety belt warning indicator electrical connector. 14. Using the special tool, install the safety belt buckle support assembly bolt. 15. Install the safety belt buckle support assembly bolt cover. 16. Position the driver seat rearward. 17. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9160 ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 18. Position the passenger seat forward. 19. Remove from vehicle prior to road use. Failure to remove can result in injury and possible violation of vehicle safety standards. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE THE RESTRAINT SYSTEM DIAGNOSTIC TOOL FROM THE PASSENGER SEAT SIDE AIR BAG FLOOR ELECTRICAL CONNECTOR. 20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 21. Position the passenger seat rearward. 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 23. Install the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9161 24. Remove the restraint system diagnostic tool from the vehicle harness side of the air bag sliding contact electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS LOT RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 25. Connect the air bag sliding contact electrical connector at the base of the steering column. 26. Position the lower steering column opening finish panel reinforcement and install the bolts. 27. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9162 28. Position the hood release handle and install the screws. 29. Connect the battery ground cable. 30. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 31. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9163 Seat Belt Buckle: Service and Repair Passenger Seat With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9164 ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced, the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. 1. Position the passenger seat rearward. 2. Remove the passenger seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9165 6. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 7. Remove the safety belt buckle support assembly bolt cover plug. 8. Using the special tool, remove the safety belt buckle support assembly bolt. 9. Remove the passenger seat rear bolt trim covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9166 10. Remove the passenger seat rear bolts. 11. Remove the passenger seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. 12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 14. Connect the battery ground cable. 15. Position the driver seat rearward. 16. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS.., SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9167 17. Remove the retaining screws and position the hood release handle out of the way. 18. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 19. Remove the bolts and remove the lower steering column opening finish panel reinforcement. 20. Disconnect the air bag sliding contact electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9168 21. Attach the restraint system diagnostic tool to the vehicle harness side of the air bag sliding contact electrical connector. 22. Remove the passenger air bag module. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 24. Connect the battery ground cable. 25. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming 26. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 27. Remove the safety belt buckle support assembly. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9169 28. Remove the safety belt buckle. 1 Clamp the safety belt buckle support assembly in a suitable vise. 2 Using the special tool, remove the safety belt buckle bolt. 3 Remove the safety belt buckle. NOTE: Clamp the safety belt buckle support assembly in a vise along the break line only. INSTALLATION WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced, the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9170 1. Install the safety belt buckle onto the safety belt buckle support assembly. 1 Position the safety belt buckle onto the safety belt buckle support assembly. 2 Using the special tool, install the safety belt buckle bolt. 3 Remove the safety belt buckle support assembly from the vise. 2. Install the safety belt buckle support assembly onto the seat. 1 Position the safety belt buckle support assembly to the seat. 2 Install the nut and bolt. 3. Position the passenger seat into the vehicle. Install and hand-tighten the four seat track to floor bolts. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. 4. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9171 5. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 6. Connect the battery ground cable. 7. Position the front seats rearward. 8. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 9. Tighten in sequence the passenger seat front track-to-floor bolts. 1 Tighten to specification the front inboard bolt. 2 Tighten to specification the front outboard bolt. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ HE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Tighten in sequence the passenger seat rear track-to-floor bolts. 1 Tighten to specification the rear inboard bolt. 2 Tighten to specification the rear outboard bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9172 13. Install the passenger seat rear track bolt covers. 14. Using the special tool, install the safety belt buckle support assembly bolt. 15. Install the safety belt buckle support assembly bolt cover. 16. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9173 17. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 18. Connect the battery ground cable. 19. Position the front seats rearward. 20. Disconnect the battery ground cable and wait at least one minute. 21. Remove the restraint system diagnostic tool from the vehicle harness side of the air bag sliding contact electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the air bag sliding contact electrical connector at the base of the steering column. 23. Position the lower steering column opening finish panel reinforcement and install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9174 24. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 25. Position the hood release handle and install the screws. 26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 27. Install the passenger air bag module. 28. Connect the battery ground cable. 29. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE CAN RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 30. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seats Without Side Air Bag > Page 9175 Seat Belt Buckle: Service and Repair Rear Seat REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the rear seats. 2. Remove the rear safety belt buckles. 1 Remove the nuts. 2 Remove the rear safety belt buckles. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Page 9176 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9184 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9185 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9186 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9187 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9188 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9189 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 9190 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation Safety Belt Extension Assembly In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt extensions are only available with black webbing. There are two extension assemblies available, one for the front seating positions and one for the rear seating positions, and they are not interchangeable. Use only extensions manufactured by the same supplier of the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for the occupant when fully extended. Do not use an extension to change the fit of the shoulder belt across the torso. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Safety Belt Shoulder Height Adjuster Bolts 40 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications > Page 9197 Seat Belt Height Adjuster: Service and Repair D-Ring Installation Kit SPECIAL TOOL(S) 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications > Page 9198 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications > Page 9199 D-Ring Installation Kit Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Application and ID Seat Belt Reminder Lamp: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 9211 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 9217 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 9218 Seat Belt Retractor: Specifications Rear Seat Center Occupant Safety Belt Retractor And Passenger Side Safety Belt Buckle Assembly Bolt 40 Nm Safety Belt Retractor Bolts 40 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 9219 Seat Belt Retractor: Service Precautions WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERITY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 9220 Seat Belt Retractor: Testing and Inspection WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERITY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. 1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in the safety belt, with the seat in the full down and rearmost position, seat back in an upright position, and if applicable, the O-ring adjusted in the full down position. 2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor (ALR) feature. Then allow the belt to retract freely in the ALR mode, and the retractor force set the correct belt tightness. 3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new belt and retractor assembly. The safety belt should remain locked in the ALR mode across an empty seat. 4. To verify that the safety belt still automatically disengages from the ALR mode correctly, with the O-ring adjusted to the full up position, if applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and retractor assembly must be installed. The safety belt should extract freely. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor Seat Belt Retractor: Service and Repair Front Safety Belt Retractor Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. All Vehicles 1. Pull to release the retaining clips and remove the windshield side garnish molding. 2. Pull up to release the retaining clips and remove the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9223 3. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. 4. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 5. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 6. Position the carpet aside at the front safety belt anchor. 7. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9224 8. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. 3 Remove the quarter trim panel front screw. 9. Fold the rear seat into the load floor position. 10. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 11. Remove the retractable cargo cover. All vehicles 12. Remove the rear safety belt guide. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9225 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. 3 Remove the rear safety belt guide. 13. Position the carpet aside at the rear safety belt anchor. 14. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 15. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 16. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9226 17. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. Vehicles with a rear power lock switch 18. Through the jack access panel, release the rear power lock switch assembly retaining tab and pull the switch through. 19. Disconnect and remove the rear power lock switch assembly. All Vehicles 20. Remove the pin-type retainers from the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9227 21. Slide the quarter trim panel forward and disengage it from the door jamb. 22. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 23. Remove the safety belt web guide. 1 Remove the bolt. 2 Remove the safety belt web guide from the B-pillar. 24. Remove the front safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the front safety belt retractor. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9228 WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. All Vehicles 1. Install the front safety belt retractor. 1 Position the front safety belt retractor to the B-pillar. 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the safety belt web guide. 1 Position the safety belt web guide to the B-pillar. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 3. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbings through the openings in the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9229 NOTE: Make sure the safety belt webbing is not twisted prior to installation. 4. Slide back and engage the edge of the quarter trim panel into the doorjamb. 5. Install the quarter trim panel rear screws. 6. Through the front door opening, install the quarter trim front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 7. Install the pin-type retainers into the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9230 8. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 9. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Vehicles with a rear power lock switch 10. Connect and install the rear power lock switch assembly into the rear quarter trim panel. All Vehicles 11. Position the washer on the rear safety belt guide bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9231 12. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 13. Fold the rear seat into the load floor position. 14. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 15. Reposition the carpet back over the floor. 16. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo cover Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9232 17. Install the retractable cargo cover. All Vehicles 18. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 19. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9233 20. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 21. Reposition the carpet at the front safety belt anchor. 22. Align the retaining clips and install the front door scuff plate. 23. Align the retaining clips and install the windshield side garnish molding. 24. Reposition the rear seat back up. 25. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9234 Seat Belt Retractor: Service and Repair Rear Safety Belt Retractor Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. All Vehicles 1. Pull to release the retaining clips and remove the windshield side garnish molding. 2. Pull up to release the retaining clips and remove the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9235 3. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. 4. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 5. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 6. Position the carpet aside at the front safety belt anchor. 7. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9236 8. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. 3 Remove the quarter trim panel front screw. 9. Fold the rear seat into the load floor position. 10. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 11. Remove the retractable cargo cover. All Vehicles 12. Remove the rear safety belt guide. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9237 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. 3 Remove the rear safety belt guide. 13. Position the carpet aside at the rear safety belt anchor. 14. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 15. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 16. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9238 17. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. Vehicles with rear power lock switch 18. Through the jack access panel, release the rear power lock switch assembly retaining tab and pull the switch through. 19. Disconnect and remove the rear power lock switch assembly. All Vehicles 20. Remove the pin-type retainers from the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9239 21. Slide the quarter trim panel forward and disengage it from the doorjamb. 22. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 23. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. All Vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9240 1. Install the rear safety belt retractor. 1 Position the rear safety belt retractor to the B-pillar. 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbings through the openings in the quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 3. Slide back and engage the edge of the quarter trim panel into the door jamb. 4. Install the quarter trim panel rear screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9241 5. Through the front door opening, install the quarter trim panel front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim panel front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 6. Install the pin-type retainers into the quarter trim panel. 7. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 8. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9242 Vehicles with rear power lock switch 9. Connect and install the rear power lock switch assembly into the rear quarter trim panel. All Vehicles 10. Position the washer on the rear safety belt guide bolt. 11. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 12. Fold the rear seat into the load floor position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9243 13. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 14. Reposition the carpet back over the floor. 15. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo covers 16. Install the retractable cargo cover. All Vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9244 17. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 18. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 19. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 20. Reposition the carpet at the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 9245 21. Align the retaining clips and install the front door scuff plate. 22. Align the retaining clips and install the windshield side garnish molding. 23. Reposition the rear seat back up. 24. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Page 9246 Seat Belt Bolt Bit (Used For T-50 Head Bolt) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9251 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Timer: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9256 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Page 9257 Seat Belt Warning Timer: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Page 9258 Seat Belt Warning Timer: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The following conditions will take place: ^ If the safety belt is not buckled before the ignition is turned to the ON position, the chime will turn on for four to eight seconds and the indicator will come on for one to two minutes. ^ If the safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. ^ If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor Bolts 12 Nm Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right > Page 9265 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 9268 Impact Sensor: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 9269 Impact Sensor: Description and Operation WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS contains two sensors which are integral to the RCM. The RCM is mounted on the center tunnel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Side Crash Sensor, Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9272 connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9273 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 7. Remove the passenger air bag module. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9274 SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9275 15. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the diagnostic tools in place at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming 19. Position the front seats to their most forward position. 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 21. Pull to release the retaining clips and remove the windshield side garnish molding. 22. Pull up to release the retaining clips and remove the front door scuff plate. 23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9276 24. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26. Position the carpet aside at the front safety belt anchor. 27. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. 28. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9277 3 Remove the quarter trim panel front screw. 29. Fold the rear seat into the load floor position. 30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 31. Remove the retractable cargo cover. All Vehicles 32. Remove the rear safety belt guide. 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. 3 Remove the rear safety belt guide. 33. Position the carpet aside at the rear safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9278 34. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 35. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 36. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. 37. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9279 38. Remove the pin-type retainers from the quarter trim panel. 39. Slide the quarter trim panel forward and disengage it from the door jamb. 40. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9280 42. Position the side crash sensor with bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side crash sensor with bracket away from the B-pillar. 43. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9281 removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Connect the side crash sensor electrical connector. 1 Position the side crash sensor. 2 Connect the side crash sensor electrical connector. 2. Install the side crash sensor. 1 Position the side crash sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest and most forward position. 8. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9282 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 9. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbings through the openings in the quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 10. Slide back and engage the edge of the quarter trim panel into the door jamb. 11. Install the quarter trim panel rear screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9283 12. Through the front door opening, install the quarter trim panel front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim panel front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 13. Install the pin-type retainers into the quarter trim panel. 14. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 15. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Vehicles with a rear power lock switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9284 16. Connect and install the rear power lock switch assembly into the rear quarter trim panel. All vehicles 17. Position the washer on the rear safety belt guide bolt. 18. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 19. Fold the rear seat into the load floor position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9285 20. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 21. Reposition the carpet back over the floor. 22. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo covers 23. Install the retractable cargo cover. All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9286 24. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 25. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 26. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 27. Reposition the carpet at the front safety belt anchor. 28. Align the retaining clips and install the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9287 29. Align the retaining clips and install the windshield side garnish molding. 30. Reposition the rear seat back upward. 31. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 32. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 33. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9288 VEHICLE SAFETY STANDARDS. 34. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 35. Connect the battery ground cable. 36. Position the front seats rearward. 37. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 38. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 39. Install the passenger air bag module. 40. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9289 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 41. Connect the clockspring electrical connector at the base of the steering column. 42. Position the lower steering column opening finish panel reinforcement and install the bolts. 43. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 44. Position the hood release handle and install the screws. 45. Connect the battery ground cable. 46. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9290 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 47. Check the restraint system for correct operation. Side Crash Sensor, Passenger Side Special Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9291 NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All Vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the passenger air bag module. 3. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 4. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9292 5. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 6. Remove the bolts and the lower steering column opening finish panel reinforcement. 7. Disconnect the clockspring electrical connector at the base of the steering column. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 9. Connect the battery ground cable. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9293 DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 14. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9294 15. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 16. Connect the battery ground cable. 17. Position the front seats rearward. 18. With the diagnostic tools in place at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming 19. Position the front seats to their most forward position. 20. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 21. Pull to release the retaining clips and remove the windshield side garnish molding. 22. Pull up to release the retaining clips and remove the front door scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9295 23. From behind the front safety belt guide bolt cover, release the retaining tab and open the cover. NOTE: The front safety belt guide has been removed for clarity. 24. Remove the front safety belt guide. 1 Using the special tool, remove the front safety belt guide bolt. 2 Remove the front safety belt guide. 25. Release the tabs and remove the safety belt guide bolt cover from the safety belt guide. 26. Position the carpet aside at the front safety belt anchor. 27. Remove the front safety belt anchor. 1 Using the special tool, remove the front safety belt anchor bolt. 2 Remove the front safety belt anchor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9296 28. Through the front door opening, remove the quarter trim panel front screw. 1 Position the rear seat back part of the way down (the seat back bar is shown). 2 Peel the carpet back between the rear seat and the quarter trim panel. 3 Remove the quarter trim panel front screw. 29. Fold the rear seat into the load floor position. 30. Carefully pull up to release the retaining clips and remove the liftgate scuff plate. Vehicles with retractable cargo cover 31. Remove the retractable cargo cover. All Vehicles 32. Remove the rear safety belt guide. 1 Peel the rear safety belt guide cover down. 2 Using the special tool, remove the rear safety belt guide bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9297 3 Remove the rear safety belt guide. 33. Position the carpet aside at the rear safety belt anchor. 34. Remove the rear safety belt anchor. 1 Using the special tool, remove the rear safety belt anchor bolt. 2 Remove the rear safety belt anchor. 35. Remove the quarter trim panel rear screws. ^ Position the carpet aside to gain access to the screws. 36. Position the rear quarter window latch out of the way. 1 Remove the two rear quarter window latch screws. 2 Position the rear quarter window latch out of the way. 37. Remove the coat hook. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9298 1 Remove the screw. 2 Remove the coat hook. 38. Remove the pin-type retainers from the quarter trim panel. 39. Slide the quarter trim panel forward and disengage it from the door jamb. 40. Remove the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Remove the quarter trim panel. 41. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9299 42. Position the side crash sensor with the bracket away from the B-pillar. 1. Remove the bolts. 2. Position the side crash sensor with the bracket away from the B-pillar. 43. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM(SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9300 removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Connect the side crash sensor electrical connector. 1 Position the side crash sensor. 2 Connect the side crash sensor electrical connector. 2. Install the side crash sensor. 1 Position the side crash sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Route the wire harness and attach the pin-type retainers to the B-pillar. 4. Connect the battery ground cable. 5. Position the front seats rearward. 6. With the diagnostic tools still in place at all deployable devices, prove out the air bag system. 7. Move and tilt the front seats to their highest and most forward position. 8. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9301 WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS. NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 9. Position the quarter trim panel into the vehicle. 1 Position the quarter trim panel into the vehicle. 2 Route the front and rear safety belt webbing through the openings in the quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 10. Slide back and engage the edge of the quarter trim panel into the door jamb. 11. Install the quarter trim panel rear screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9302 12. Through the front door opening, install the quarter trim panel front screw. 1 Position the rear seat back part of the way up (the seat back bar shown). 2 Install the quarter trim panel front screw. 3 Reposition the carpet back between the rear seat and the quarter trim panel. 13. Install the pin-type retainers into the quarter trim panel. 14. Install the rear quarter window latch. 1 Position the rear quarter window latch. 2 Install the two screws. 15. Install the coat hook. 1 Position the coat hook. 2 Install the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9303 16. Position the washer on the rear safety belt guide bolt. 17. Install the rear safety belt guide. 1 Position the rear safety belt guide. 2 Using the special tool, install the rear safety belt guide bolt. 3 Reposition the rear safety belt guide cover around the safety belt guide. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 18. Fold the rear seat into the load floor position. 19. Install the rear safety belt anchor. 1 Position the rear safety belt anchor so that the anti-rotation tab is seated in the seat bracket slot. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 20. Reposition the carpet back over the floor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9304 21. Align the retaining clips and install the liftgate scuff plate. Vehicles with retractable cargo covers 22. Install the retractable cargo cover. All Vehicles 23. Install the front safety belt guide bolt cover onto the front safety belt guide, seating all the retaining tabs. NOTE: If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 24. Install the front safety belt guide. 1 Position the front safety belt guide. 2 Using the special tool, install the front safety belt guide bolt. 3 Close the front safety belt guide bolt cover. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9305 ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. ^ If the safety belt guide cover is damaged or if it does not remain closed, install a new cover. 25. Install the front safety belt anchor. 1 Position the front safety belt retractor. 2 Using the special tool, install the front safety belt anchor bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 26. Reposition the carpet at the front safety belt anchor. 27. Align the retaining clips and install the front door scuff plate. 28. Align the retaining clips and install the windshield side garnish molding. 29. Reposition the rear seat back upward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9306 30. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 31. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 32. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 33. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9307 34. Connect the battery ground cable. 35. Position the front seats rearward. 36. Disconnect the battery ground cable and wait at least one minute. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 37. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 38. Connect the clockspring electrical connector at the base of the steering column. 39. Position the lower steering column opening finish panel reinforcement and install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9308 40. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 41. Position the hood release handle and install the screws. 42. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 43. Install the passenger air bag module. 44. Connect the battery ground cable. 45. With all the diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 46. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9309 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must be installed in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair-"J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts in Weld Nut Repair- "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 9310 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Page 9311 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safing sensor is internal to the RCM and is not serviced separately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair REMOVAL NOTE: Antenna lead-in runs from audio unit to connector behind glove box. 1. Remove the audio unit. 2. Remove the antenna lead-in cable. 1 Open the glove box door. 2 Release the tabs and lower the glove box door to the full open position. 3 Release the antenna lead-in cable clips. 4 Disconnect the connector. 5 Separate the antenna cable from the lead-in cable and remove the lead-in cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Passive Anti-Theft Transceiver Alarm System Transponder: Diagrams Passive Anti-Theft Transceiver Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Passive Anti-Theft Transceiver > Page 9332 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Page 9333 Alarm System Transponder: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, remove the tilt wheel handle. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Page 9334 5. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. 6. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the bolts. 2 Remove the instrument panel steering column opening cover reinforcement. 7. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: ^ The steering wheel has been removed for clarity. ^ Only apply pressure or leverage below the key cylinder lower rib. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9340 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9341 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9342 Keyless Entry Key-Pad: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9343 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Remove the front door speaker. 2. Disconnect the keyless entry electrical connector. 3. Remove the two wiring harness locators. 4. Release the retaining clip. 5. Remove the key less entry keypad. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9354 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9355 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9356 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9357 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9358 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9363 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9364 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9365 Keyless Entry Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9366 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9367 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9368 Keyless Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9369 Keyless Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9370 Keyless Entry Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module Multifunction Electronic Control Modules: Locations Central Security Module Vehicles Built AFTER 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 9375 Multifunction Electronic Control Modules: Locations Generic Electronic Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 9376 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 9377 Multifunction Electronic Control Modules: Locations Remote Anti-Theft Personality Module Vehicles Built BEFORE 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9380 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9381 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9382 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9383 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9384 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9385 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9386 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9387 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9388 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9389 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9390 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9391 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9392 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9393 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9394 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9395 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9396 Multifunction Electronic Control Modules: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9397 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9398 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9399 Multifunction Electronic Control Modules: Connector Views Central Security Module Vehicles Built AFTER 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9400 Generic Electronic Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9401 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9402 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9404 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9405 Remote Anti-Theft Personality Module Vehicles Built BEFORE 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9406 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9407 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9408 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 419-10-00-1 Diagram 419-10-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9409 Diagram 419-10-00-3 Diagram 419-10-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 9410 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into, the new module once installed. ^ Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description Module Controlled Functions NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. The multifunction module consists of the following: ^ Generic Electronic Module (GEM) ^ Remote Anti-theft Personality (RAP) module (vehicles built before 7/24/2000) ^ central security module (vehicles built after 7/24/2000) The GEM controls the following features: ^ front wiper and washer ^ rear wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp The remote anti-theft personality (RAP)/central security module controls the following features: ^ remote keyless entry ^ computer-operated locks Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 9413 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) Central Security Module The central security module controls the following features: ^ remote key less entry system ^ computer-operated lock system Generic Electronic Module (Gem) NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal. The GEM receives inputs and delivers outputs to a majority of the electronically controlled features of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool through the ISO 9141 communication network. The GEM controls the following features: ^ front wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp Remote Anti-Theft Personality (RAP) Module The Remote Anti-theft Personality (RAP) module controls the following features: ^ remote keyless entry system ^ computer-operated lock system Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview Central Security Module (CSM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25 A) - 11 (7.5 A) ^ Wiring harness Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Generic Electronic Module (GEM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 10 (7.5A) - 20 (7.5A) - 25 (7.5A) - 28 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Remote Anti-Theft Personality (RAP) Module 1. Verify the customer concern by operating the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9416 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25A) - 11 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test C. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9417 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Chart B1213 - B1322 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9418 DTC Chart B1322 - B1345 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9419 DTC Chart B1347 - B1450 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9420 DTC Chart B1453 - B1602 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9421 DTC Chart B1610 - B1932 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9422 DTC Index B1933 - B2477 DTC Index B2477 - C1230 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9423 C1233 - P1826 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9424 P1827 - U2018 .. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9425 Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9426 Multifunction Electronic Control Modules: Pinpoint Tests B1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9427 B1 - B2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9428 A1 - A2 A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9429 C1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9430 C1 - C2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module Multifunction Electronic Control Modules: Service and Repair Central Security Module REMOVAL CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel. 3. Disconnect the electrical connectors. 4. Remove the central security module. 1 Remove the bolts. 2 Remove the central security module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module > Page 9433 Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP) Module REMOVAL 1. Disconnect the battery ground cable. 2. Remove the back panel trim panel. 3. Disconnect the electrical connectors. 4. Remove the RAP module. 1 Remove the bolts. 2 Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module > Page 9434 Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into, the new module once installed. 2. Remove the radio chassis. Refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM. 1 Remove the bolt. 2 Disconnect the electrical connectors from the GEM. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Page 9435 Multifunction Electronic Control Modules: Tools and Equipment Special Tool(s) Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9449 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9450 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9451 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9452 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9453 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9454 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9455 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9461 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9462 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9463 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9464 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9465 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9466 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9467 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Page 9471 Remote Control: Service and Repair REMOVAL 1. Disconnect the battery. 2. Remove the console compartment trim panel screws. 3. Remove the console compartment door hinge screw. 4. Remove the console rear panel screws at the top of the panel. 5. Remove the console rear panel screws at the cup holder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Page 9472 6. Remove the rear integrated control panel screws. 7. Disconnect the floor/panel control arm at the control head. 8. Disconnect the rear blower motor control and rear radio controls electrical connectors. INSTALLATION 1. To install, reverse removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9481 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9482 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9483 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9484 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9485 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9486 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9487 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9493 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9494 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9495 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9496 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9497 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9498 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9499 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9500 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Speaker: Diagrams Left Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left > Page 9503 Speaker: Diagrams Right Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 9504 Speaker: Description and Operation All vehicles are equipped with four premium radio speakers mounted in the right rear quarter panel. The front speakers are mounted in the front doors. The rear speakers are mounted in rear doors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers Speaker: Service and Repair Door Mounted Speakers REMOVAL 1. Remove the front door trim panels. 2. Remove the speakers. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the speakers. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers > Page 9507 Speaker: Service and Repair Subwoofer Speaker REMOVAL 1. Remove the quarter trim panel. 2. Remove the subwoofer. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the subwoofer. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module Multifunction Electronic Control Modules: Locations Central Security Module Vehicles Built AFTER 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 9516 Multifunction Electronic Control Modules: Locations Generic Electronic Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 9517 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Central Security Module > Page 9518 Multifunction Electronic Control Modules: Locations Remote Anti-Theft Personality Module Vehicles Built BEFORE 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9521 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9522 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9523 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9524 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9525 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9526 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9527 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9528 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9529 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9530 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9531 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9532 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9533 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9534 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9535 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9536 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9537 Multifunction Electronic Control Modules: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9538 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9539 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9540 Multifunction Electronic Control Modules: Connector Views Central Security Module Vehicles Built AFTER 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9541 Generic Electronic Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9542 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9543 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9544 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9545 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9546 Remote Anti-Theft Personality Module Vehicles Built BEFORE 7/24/2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9547 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9548 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9549 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 419-10-00-1 Diagram 419-10-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9550 Diagram 419-10-00-3 Diagram 419-10-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 9551 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into, the new module once installed. ^ Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description Module Controlled Functions NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. The multifunction module consists of the following: ^ Generic Electronic Module (GEM) ^ Remote Anti-theft Personality (RAP) module (vehicles built before 7/24/2000) ^ central security module (vehicles built after 7/24/2000) The GEM controls the following features: ^ front wiper and washer ^ rear wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp The remote anti-theft personality (RAP)/central security module controls the following features: ^ remote keyless entry ^ computer-operated locks Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 9554 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) Central Security Module The central security module controls the following features: ^ remote key less entry system ^ computer-operated lock system Generic Electronic Module (Gem) NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal. The GEM receives inputs and delivers outputs to a majority of the electronically controlled features of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool through the ISO 9141 communication network. The GEM controls the following features: ^ front wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp Remote Anti-Theft Personality (RAP) Module The Remote Anti-theft Personality (RAP) module controls the following features: ^ remote keyless entry system ^ computer-operated lock system Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview Central Security Module (CSM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25 A) - 11 (7.5 A) ^ Wiring harness Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Generic Electronic Module (GEM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: - 10 (7.5A) - 20 (7.5A) - 25 (7.5A) - 28 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Remote Anti-Theft Personality (RAP) Module 1. Verify the customer concern by operating the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9557 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25A) - 11 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test C. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate Vehicle System to continue diagnostics. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9558 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Chart B1213 - B1322 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9559 DTC Chart B1322 - B1345 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9560 DTC Chart B1347 - B1450 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9561 DTC Chart B1453 - B1602 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9562 DTC Chart B1610 - B1932 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9563 DTC Index B1933 - B2477 DTC Index B2477 - C1230 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9564 C1233 - P1826 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9565 P1827 - U2018 .. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9566 Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9567 Multifunction Electronic Control Modules: Pinpoint Tests B1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9568 B1 - B2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9569 A1 - A2 A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9570 C1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9571 C1 - C2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module Multifunction Electronic Control Modules: Service and Repair Central Security Module REMOVAL CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel. 3. Disconnect the electrical connectors. 4. Remove the central security module. 1 Remove the bolts. 2 Remove the central security module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module > Page 9574 Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP) Module REMOVAL 1. Disconnect the battery ground cable. 2. Remove the back panel trim panel. 3. Disconnect the electrical connectors. 4. Remove the RAP module. 1 Remove the bolts. 2 Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Central Security Module > Page 9575 Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into, the new module once installed. 2. Remove the radio chassis. Refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM. 1 Remove the bolt. 2 Disconnect the electrical connectors from the GEM. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Page 9576 Multifunction Electronic Control Modules: Tools and Equipment Special Tool(s) Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9582 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9583 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9584 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9585 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9586 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9587 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9588 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9589 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9590 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9591 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9592 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9593 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9594 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9595 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9596 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9597 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9598 Keyless Entry Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9599 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9600 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9601 Keyless Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9602 Keyless Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9603 Keyless Entry Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Page 9608 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer tow lamps. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 3 (7.5A) - 7 (7.5A) - 36 (15A) ^ Circuitry ^ Trailer tow relay ^ Bulb(s) 4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9613 Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9614 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to Vehicle/Diagrams for schematic and connector information. V1 W1 - W2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9615 W2 X1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9616 X1 Y1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9617 Z1 - Z2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9618 Z2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9619 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 9620 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Page 9624 Trailer Lighting Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Page 9625 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Page 9629 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT BUMPER COVER Removal and Installation 1. Remove the radiator grille sight shield. 1. Remove the bolts. 2. Release the retaining clips. 3. Remove the radiator grille sight shield. 2. Remove the two parking lamp assemblies. 1. Remove the two bolts (one each side). 2. Remove the two parking lamp assemblies. - Disconnect the electrical connectors. 3. Remove the two headlamp assemblies. 1. Pull upward to release the four tabs (two each side). 2. Remove the two headlamp assemblies. - Disconnect the electrical connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 9636 4. Remove the three lower radiator air deflector bolts. 5. Remove the six fender splash shield screws (three each side). 6. Remove the two front bumper cover bolts from inside the fender opening (one each side). 7. Remove the front bumper cover. - Unclip the six locking tabs. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair Front Bumper Reinforcement: Service and Repair FRONT BUMPER Removal and Installation 1. Remove the front bumper cover. 2. If equipped, remove the two fog lamp assemblies. 1. Disconnect the electrical connectors. 2. Remove the six bolts (three each side). 3. Remove the two fog lamp assemblies. 3. WARNING: To avoid possible injury, support the front bumper before removing the nuts. Remove the four nuts (two each side) and the front bumper. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Bracket > System Information > Service and Repair Rear Bumper Bracket: Service and Repair BUMPER BRACKET - REAR, SPORT TRAC Removal and Installation 1. Remove the rear bumper cover. 2. NOTE: This step may require an assistant. Remove the rear bumper assembly. 1. Remove the four rear bumper bracket to frame nuts (two each side). 2. Remove a stud plate from one side. 3. Remove the rear bumper assembly 3. Remove the rear bumper bracket assembly. 1. Remove the rear bumper beam nuts. 2. Remove the rear bumper hitch plate to rear bumper beam bracket nuts and bolts. 3. Remove the rear bumper bracket assembly. 4. Remove the nuts, stud plate, and separate the rear bumper brackets. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR BUMPER COVER Special Tool(s) Special Tool(s) Removal and Installation 1. Disconnect the two license plate lamps. 2. Remove the four splash shield screws (two each side). 3. Remove the two rear bumper cover rivets (one each side). 4. NOTE: Align the rear bumper cover to the rear bumper beam guide holes when installing the step pads Remove the two step pads (one each side). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 9647 5. Remove the rear bumper cover. 6. To install, reverse the removal procedure. - Using the special tool, install the new rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair Rear Bumper Reinforcement: Service and Repair REAR BUMPER - HITCH PLATE, SPORT TRAC Removal and Installation 1. Remove the rear bumper cover. 2. NOTE: - This step may require an assistant. - Disconnect the trailer tow wiring harness. Remove the rear bumper hitch plate. 1. Remove the six nuts and bolts (three each side). 2. Remove the two nuts and bolts (one each side). 3. Remove the rear bumper hitch plate. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Position the watershield aside. 3. Disconnect the exterior handle actuating rod. 1 Open the clip. 2 Disconnect the exterior door handle actuating rod. 4. Remove the rivets and the exterior door handle. INSTALLATION 1. To install, reverse the removal procedure. - Using the special tool, install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 9662 Heavy - Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Position the watershield aside. 3. Remove the interior door handle screws. 4. Remove the interior door handle. 1 Release the actuating rod. 2 Remove the interior door handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments Front Door Hinge: Adjustments HINGE ADJUSTMENT - FRONT DOOR NOTE: - Check the rear door hinge adjustment before adjusting the front door hinge. - Explorer Sport Trac shown Explorer Sport similar. 1. Remove the A-pillar lower trim panel. 2. Position the electrical connector mounting bracket aside. 1. Remove the pin-type retainer. 2. Position the electrical connector mounting bracket aside. 3. Mark the position of the front door hinges to use as a reference point. 4. NOTE: Position the front door to gain access to the bolts. Loosen the two front door hinge to body bolts and nuts just enough to permit movement of the door. 5. Adjust the front door alignment to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 9669 6. Tighten the front door hinge to body bolts and nuts. 7. Install the electrical connector mounting bracket. 1. Install the electrical connector mounting bracket. 2. Install the pin-type retainer. 8. Install the A-pillar lower trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Front Door Latch: Service and Repair Front SPECIAL TOOL(S) Heavy Duty Riveter REMOVAL 1. Remove the interior door handle. 2. Remove the door glass run channel. 1 Remove the bolt. 2 Remove the door glass run channel. Release the wiring harness locator. 3. Remove the screws and position the front door latch aside. - Discard the screws. 4. Release the exterior door handle actuating rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front > Page 9674 1 Open the clip. 2 Release the exterior door handle actuating rod. 5. Disconnect the front door lock cylinder rod. 6. If equipped, remove the door lock actuator rivet. 7. If equipped, disconnect the door lock actuator electrical connector. 8. Remove the front door latch. 1 Disconnect the door ajar switch electrical connector. 2 Disconnect the ground wire. 3 Remove the front door latch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front > Page 9675 9. Remove the front door latch actuating rods. 1 Remove the door lock cylinder actuating rod. 2 Remove the push button lock actuating rod. 3 Remove the interior latch remote control actuating rod. 10. If equipped, remove the door lock actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use the special tool to install the rivet. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front > Page 9676 Front Door Latch: Service and Repair Push Button Rod Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the rear door latch. 2. Remove the rear door push button rod remote control. 1 Remove the rivet. 2 Release the clip and remove the rear door push button rod remote control. 3. Remove the push button rod. 1 Open the Clip. 2 Remove the push button rod. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 9677 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair FRONT DOOR TRIM PANEL Removal and Installation High Series Door Trim Panels 1. Disconnect the battery ground cable. 2. Remove the front door window control switch panel. - Disconnect the electrical connectors. All Door Trim Panels 3. Remove the door handle cup screws. 4. Remove the door handle cup. Low Series Door Trim Panels 5. Remove the screw and the window regulator handle. All Door Trim Panels Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 9681 6. Remove the front door trim panel. 1. Remove the screws. 2. Remove the front door trim panel. If equipped, disconnect the exterior mirror control switch electrical connector. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Remove the front door belt line moulding. 1 Remove the nut. 2 Remove the moulding. CAUTION: Do not strike or force the front door belt line moulding during installation. The front door belt line moulding is made of aluminum and will be damaged. NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge of the sheet metal and the door panel shelf. 3. Remove the interior glass weatherstrip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 9685 4. Remove the front door window glass rivets. NOTE: Lower the window glass to access the rivets. 5. Remove the front door window glass through the outboard side of the front door. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 9690 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 9691 Front Door Window Motor: Service Precautions CAUTION: Use care not to damage the drum housing when removing the rear window glass motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 9692 Front Door Window Motor: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 3. Remove the water shield. 4. Disconnect the front door window regulator motor electrical connector. 5. Drill a 13 mm (0.52 in) hole using the locator in the door sheet metal as a guide. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 9693 6. Remove the bolts and the front door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the interior door handle. 3. Support the front door window glass. 4. Disconnect the front door window regulator motor electrical connector. 5. Remove the equalizer bracket nuts. 6. Remove the front door window regulator. 1 Remove the rivets. 2 Remove the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9697 7. Remove the front door window regulator motor. 1 Remove the bolts. 2 Remove the front door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9698 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Position the watershield aside. 3. Disconnect the exterior handle actuating rod. 1 Open the clip. 2 Disconnect the exterior door handle actuating rod. 4. Remove the rivets and the exterior door handle. INSTALLATION 1. To install, reverse the removal procedure. - Using the special tool, install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Position the watershield aside. 3. Remove the interior door handle screws. 4. Remove the interior door handle. 1 Release the actuating rod. 2 Remove the interior door handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments Rear Door Hinge: Adjustments HINGE ADJUSTMENT - REAR DOOR 1. Remove the front seat safety belt retractor. 2. Mark the position of the rear door hinges to use as a reference point. 3. Loosen the rear door hinge to body nuts just enough to permit movement of the door. 4. Adjust the rear door alignment to specification. 5. Tighten the rear door hinge to body nuts. 6. Check the front door adjustments. 7. Install the front seat safety belt retractor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Push Button Rod Rear Door Latch: Service and Repair Push Button Rod Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the rear door latch. 2. Remove the rear door push button rod remote control. 1 Remove the rivet. 2 Release the clip and remove the rear door push button rod remote control. 3. Remove the push button rod. 1 Open the Clip. 2 Remove the push button rod. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Push Button Rod > Page 9714 Rear Door Latch: Service and Repair Rear Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the interior door handle. 2. Disconnect the push button actuating rod. 1 Release the Clip. 2 Disconnect the push button actuating rod. 3. Disconnect the exterior door handle actuating rod. 1 Open the clip. 2 Disconnect the exterior door handle actuating rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Push Button Rod > Page 9715 4. Remove the rear door latch screws. - Discard the screws. 5. If equipped, remove the rear door lock actuator rivets. - Disengage the wiring harness locator. 6. If equipped, disconnect the rear door lock actuator electrical connector. 7. Remove the rear door latch. 1 Disconnect the door ajar switch electrical connector. 2 Disconnect the ground wire. 8. Disconnect the rear door latch actuating rods. 1 Disconnect the interior door handle actuating rod. 2 If equipped, remove the door lock actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use the special tool to install the rivets. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 9716 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair REAR DOOR TRIM PANEL Removal and Installation High Series Door Trim Panels 1. Remove the rear door window control switch panel. - Disconnect the electrical connector. All Door Trim Panels 2. Remove the door handle cup screws. 3. Remove the door handle cup. Low Series Door Trim Panels 4. Remove the screw and the window regulator handle. All Door Trim Panels Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 9720 5. Remove the rear door trim panel. 1. Remove the screw. 2. Remove the rear door trim panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Remove the rear door trim panel. 2. Remove the interior glass weatherstrip. 3. Remove the rear door belt line moulding nut. 4. Remove the rear door belt line moulding. CAUTION: Do not strike or force the front door belt line moulding during the installation. The front door belt line moulding is made of aluminum and will be damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 9724 NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge of the sheet metal and the door panel shelf. 5. Remove the rear door window glass rivets. 6. Remove the rear door window glass through the outboard side of the rear door. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Left Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Left > Page 9729 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Left > Page 9730 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Page 9731 Rear Door Window Motor: Service Precautions CAUTION: Use care not to damage the drum housing when removing the rear window glass motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor Rear Door Window Motor: Service and Repair Rear Door Window Regulator Motor REMOVAL 1. Remove the rear door window regulator. 2. Remove the rear door window regulator motor. 1 Remove the bolts. 2 Remove the rear door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 9734 Rear Door Window Motor: Service and Repair Rear Window Glass Motor REMOVAL 1. Remove the C-pillar trim panel. 2. Position the rear of the carpet aside. 3. Remove the water shield from over the rear window glass motor and discard. 4. Remove the rear window motor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the rear window glass motor. CAUTION: Use care not to damage the drum housing when removing the rear window glass motor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The rear window motor must be initialized after a repair is carried out. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 9735 Rear Door Window Motor: Service and Repair Rear Window Motor Initialization 1. Start with the ignition key in the OFF position. 2. Turn the ignition key to the ON position. 3. Press the rear window glass control switch vent button six times. 4. Turn the ignition key to the OFF position. 5. Press the rear window glass control switch vent button six more times. 6. Turn the ignition key to the ON position. At this point the rear window glass will move up and down approximately 20 mm (0.8 in). This movement signifies that the rear window glass motor has entered into the initialization mode. 7. Hold the rear window glass control switch in the full up position until the rear window glass stops in the full up position. NOTE: The rear window glass control switch must be held in the up or down position until the window glass stops moving. Failure to hold the switch will end the initialization operation. Then initialization will have to be re-started. 8. Hold the rear window glass control switch in the full down position until the rear window glass stops in the full down position. NOTE: If a repair is to be carried out on the rear window glass release the rear window glass control switch when it reaches the desired position. This will end the initialization operation. 9. Hold the rear window glass control switch in the full, up position until the rear window glass stops in the full up position. At this time the window will move up and down approximately 20 mm (0.8 in) signifying the rear window glass motor is initialized. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Raise and support the rear door window glass to the full up position. 2. Remove the interior door handle. 3. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 4. Remove the water shield. 5. Disconnect the rear door window regulator motor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9739 6. Remove the rear door window regulator rivets. 7. Remove the rear door window regulator. ^ Slide the regulator arms off of the window glass track. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9740 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Technical Service Bulletins > Recalls for Hood Latch: > NHTSA00V394000 > Nov > 00 > Recall 00V394000: Hood Striker Fracture/Failure Hood Latch: Recalls Recall 00V394000: Hood Striker Fracture/Failure Sport utility vehicles with steel hoods and certain pickup trucks equipped with sheet molding compound hoods. A wire formed hood striker could be susceptible to fatigue fractures. If the hood striker fractures, the hood could fly open while the vehicle is being driven. A hood fly-up while the vehicle is being operated could result in reduced driver visibility. Dealers will replace the hood striker. Owner notification is expected to begin during December 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Latch: > NHTSA00V394000 > Nov > 00 > Recall 00V394000: Hood Striker Fracture/Failure Hood Latch: All Technical Service Bulletins Recall 00V394000: Hood Striker Fracture/Failure Sport utility vehicles with steel hoods and certain pickup trucks equipped with sheet molding compound hoods. A wire formed hood striker could be susceptible to fatigue fractures. If the hood striker fractures, the hood could fly open while the vehicle is being driven. A hood fly-up while the vehicle is being operated could result in reduced driver visibility. Dealers will replace the hood striker. Owner notification is expected to begin during December 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Technical Service Bulletins > Page 9755 Hood Latch: Service and Repair REMOVAL 1. Remove the radiator grille sight shield. 1 Remove the bolts. 2 Release the retaining clips. 3 Remove the radiator grille sight shield. 2. Remove the bolts and position the hood latch aside. 3. Remove the hood latch. 1 Release the cable conduit. 2 Release the hood latch cable. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Technical Service Bulletins > Page 9756 1. Install the hood latch cable. 1 Install the hood latch cable. 2 Install the cable conduit. 2. Position the hood latch and install the bolts. 3. Align the hood latch. 1 loosen the hood latch bolts enough to allow for movement of the hood latch. 2 Align the hood latch with the hood latch striker. 4. Tighten the hood latch bolts. 5. Verify the hood latch striker is fully engaging the hood latch. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latch. - Repeat the install procedure as necessary to make sure the hood latch is aligned correctly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Technical Service Bulletins > Page 9757 6. Install the radiator grille sight shield. 1 Position the sight shield. 2 Lock the clips. 3 Install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair REMOVAL 1. Remove the hood latch. 2. Remove the hood latch release handle screws. 3. Release the hood latch release cable. 1 Disconnect the cable conduit. 2 Release the cable. 4. Remove the two hood latch release handle cable locators. 5. Pull the hood latch release handle cable towards the engine compartment and remove the cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest for Hood Latch Release Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Hood Latch Release Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest for Hood Latch Release Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 9769 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Latch Release Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Hood Latch Release Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Latch Release Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 9775 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 9781 OASIS CODES: 201000, 201200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Open the liftgate glass. 2. Remove the two heated rear window electrical connector covers. 3. Disconnect the two heated rear window electrical connectors. 4. Remove the two liftgate lifting cylinder pins. NOTE: An assistant may be needed to carry out this step. 5. Remove the liftgate window glass. 1 Position the liftgate trim panel aside. 2 Remove the access the covers and the liftgate window hinge nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 9786 NOTE: An assistant may be needed to carry out this step. 6. Remove the liftgate window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair SPECIAL TOOL(S) Heavy Duty Riveter REMOVAL 1. Remove the liftgate trim panel. 2. Remove the air escape vent panel. 1 Remove the pin-type retainers. 2 Remove the air escape vent panel. 3. Position the watershield aside. 4. Disconnect the liftgate release handle actuating rod. 1 Open the clip. 2 Disconnect the liftgate release handle actuating rod. 5. Remove the license plate lamp shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Page 9793 1 Remove the screws. 2 Remove the license plate lamp shield. 6. Remove the liftgate release handle. 1 Remove the rivets. 2 Remove the liftgate release handle. INSTALLATION 1. To install, reverse the removal procedure. - Using the special tool, install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Page 9794 Heavy - Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair LIFTGATE TRIM PANEL Removal and Installation 1. Open the liftgate glass. 2. Remove the liftgate handle. 1. Remove the liftgate handle screws. 2. Remove the liftgate handle. 3. Remove the liftgate trim panel screw access plug. 4. Remove the liftgate trim panel screw. 5. Remove the liftgate trim panel. 1. Remove the liftgate trim panel from the liftgate window opening. 2. Push the liftgate trim panel toward the top of the liftgate and remove the liftgate trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Page 9798 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch Trunk / Liftgate Latch: Service and Repair Liftgate Latch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the liftgate trim panel. 3. Remove the air escape vent panel. 1 Remove the pin-type retainers. 2 Remove the air escape vent panel. 4. Remove the watershield. 5. Disconnect the liftgate latch release rod from the liftgate latch remote control. 1 Open the clip. 2 Disconnect the liftgate latch release rod. 6. Remove the liftgate latch. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the liftgate latch and the liftgate release rod. INSTALLATION 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. NOTE: If installation of a new liftgate latch release rod is necessary, be sure to match the color coded rods for correct installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9803 - Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. - Position the liftgate latch release rod by pushing outboard to remove the slack. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9804 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control REMOVAL 1. Remove the liftgate latch actuator. 2. Remove the liftgate latch remote control from the liftgate. - Transfer parts as necessary. 3. To install, reverse the removal procedure. NOTE: Make sure the liftgate handle actuating rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9805 Trunk / Liftgate Latch: Service and Repair Liftgate window Latch REMOVAL 1. Disconnect the battery ground cable. 2. Open the liftgate window glass. 3. Remove the liftgate trim panel. 4. Remove the air escape vent panel. 1 Remove the pin-type retainers. 2 Remove the air escape vent panel. 5. Remove the watershield. 6. Disconnect the liftgate window latch actuating rod. 1 Open the clip. 2 Disconnect the liftgate window latch actuating rod. 7. Disconnect the liftgate window ajar switch electrical connector and remove the nuts. NOTE: Mark the position of the liftgate window latch prior to removing the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9806 8. Remove the liftgate window latch. INSTALLATION 1. Position the liftgate window latch and loosely install the nuts. 2. Move the liftgate window glass to the closed position. 3. Adjust the liftgate window latch. - Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush. 4. Tighten the liftgate window latch nuts. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9807 5. Connect the liftgate window latch actuating rod. 1 Connect the liftgate window latch actuating rod. 2 Lock the clip. 6. Verify the liftgate window glass adjustment. INSTALLATION 1. Install the watershield. 2. Install the air escape vent panel. 1 Position the air escape vent panel. 2 Install the pin-type retainers. 2. Install, the liftgate trim panel. 3. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the liftgate latch remote control. 2. Remove the liftgate lock cylinder. 1 Remove the nuts. 2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair Trunk / Liftgate Solenoid: Service and Repair REMOVAL 1. Remove the liftgate window latch. 2. Disconnect the liftgate latch release rods. 1 Open the clips. 2 Disconnect the liftgate latch release rods. 3. Disconnect the liftgate release handle actuating rod. 1 Open the clip. 2 Disconnect the liftgate release handle actuating rod. 4. Disconnect the lock cylinder actuating rod. 1 Open the clip. 2 Disconnect the lock cylinder actuating rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Page 9814 5. Remove the liftgate lock remote control bolt. 6. Disconnect the liftgate lock actuator electrical connector. 7. Remove the liftgate lock actuator nuts. 8. Move the liftgate latch remote control to the LH opening and remove the liftgate latch actuator. INSTALLATION 1. Connect and position the liftgate latch actuator. 2. Install the liftgate latch actuator nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Page 9815 3. Connect the liftgate latch actuator electrical connector. 4. Position the liftgate latch remote control. 5. Loosely install the liftgate latch remote control bolt. 6. Position the liftgate window latch and loosely install the nuts and connect the electrical connector. 7. Move the liftgate window glass to the closed position. 8. Adjust the liftgate window latch. - Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Page 9816 9. Tighten the liftgate window latch nuts. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. 10. Connect the liftgate window latch actuating rod. 1 Connect the liftgate window latch actuating rod. 2 Lock the clip. 11. Verify the liftgate window glass adjustment. 12. Tighten the liftgate latch remote control bolt. 13. Connect the lock cylinder actuating rod. 1 Position the lock cylinder actuating rod. 2 Close the clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Page 9817 NOTE: Be sure the bell crank of the liftgate latch remote control is in the unlocked position (upward) for correct lock cylinder rod length. 14. Connect the liftgate release handle actuating rod. 1 Position the liftgate release handle actuating rod. 2 Close the clip. NOTE: Make sure the liftgate release handle actuating rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. 15. Connect the liftgate latch release rods. 1 Position the liftgate latch release rods by pushing outboard to remove the slack. 2 Close the clips. NOTE: Make sure the latch release rods are not preloading the liftgate latch. They should be clipped in a relaxed state with no slack. 16. Install the watershield. 17. Install the air escape vent panel. 1 Position the air escape vent panel. 2 Install the pin-type retainers. 18. Install the liftgate trim panel. 19. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Ajar Switch Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9822 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 9823 Trunk / Liftgate Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 9824 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FENDER SPLASH SHIELD Removal and Installation Both Sides 1. Remove the fender splash shield front bolts. 2. Remove the fender splash shield screws. LH Side 3. From inside the engine compartment, disconnect the wiring harness retainers from the fender splash shield. 4. Remove the ABS module nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 9834 RH Side 5. Position the vacuum reservoir aside. 1. Remove the bolts. 2. Position the vacuum reservoir aside. 6. Remove the fender splash shield bolts. Both Sides 7. Remove the fender splash shield. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation FRAME AND BODY MOUNTING Explorer Sport/Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9839 Explorer Sport/Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9840 Explorer Sport/Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9841 Explorer Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9842 Explorer Sport The frame consists of two steel channel rails, a rear crossmember, additional support crossmembers and a front crossmember. The rails and crossmembers are not to be removed from the frame to be repaired. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair RADIATOR GRILLE Removal and Installation 1. Remove the front bumper cover. 2. Remove the radiator grilles. 1. Remove the four pin-type retainers. 2. Release the six clips. 3. Remove the radiator grilles. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Torque Specifications, Part 1 Torque Specifications, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 9850 Console: Description and Operation Overhead Console The overhead console consists of the following components: compass/thermometer display - garage door opener storage (without roof opening panel) - map/courtesy lamps - map/courtesy lamp switch - roof opening panel control switch (with roof opening panel) Floor Console The high series floor console consists of the following components: armrest - ashcup - bin mat - console finish panel - coin holder - power point - cup holder insert - storage compartment - rear cup holders - rear integrated control panel The base floor console consists of the following components: arm rest - carry bag - front cup holders - rear cup holders If the vehicle is equipped with manual transmission, there will be a consolette at the base of the gearshift lever. The consolette contains two cupholders, covers the Restraint Control Module (RCM) and is attached by two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Base Series Console: Service and Repair Floor Console - Base Series REMOVAL 1. Remove the front seat center armrest. 1 Remove the two covers. 2 Remove the four bolts. 3 Remove the armrest. 2. Remove the utility tray beverage holder. 3. Remove the floor console. 1 Remove the screws. 2 Remove the floor console. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Base Series > Page 9853 Console: Service and Repair Floor Console - High Series REMOVAL 1. Disconnect the battery ground cable. 2. Remove the floor console tray. - Lift upward at the rear first. 3. Disconnect the floor console electrical connectors. 4. Remove the floor console front bolts. 5. Remove the floor console center bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Base Series > Page 9854 6. Remove the floor console. NOTE: The console must be moved rearward to disengage the rear mounting bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Base Series > Page 9855 Console: Service and Repair Overhead Console REMOVAL 1. Disconnect the battery ground cable. 2. If equipped, open the garage door remote cover. 3. If equipped, remove the screws. 4. Remove the overhead console. NOTE: On vehicles equipped with a roof opening panel the overhead console is a snap-fit. 5. Disconnect the electrical connector (two connectors on vehicles equipped with a roof opening panel). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Base Series > Page 9856 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor connector. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side floor connector. 11. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9862 STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector beneath the front seat. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag electrical connector beneath the front seat. 11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat. 12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side air bag electrical connector beneath the front seat. 13. Reconnect the battery ground cable. Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9863 NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9864 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9865 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9866 Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9867 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9868 Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9869 14. Install the two screws. 15. Close the glove compartment door. 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9870 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Procedures For Repair Operations Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9871 accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9872 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9873 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9874 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9875 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic tool from the driver seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9876 8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. Prove out the system. Seats Not Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the front passenger seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the driver seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver seat. 10. Reconnect the battery ground cable. 11. Prove out the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9877 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9878 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures Headliner: Procedures REMOVAL All Vehicles 1. Disconnect the battery ground cable. Sport Trac 2. Remove the C-pillar trim panel. Explorer Sport 3. Remove the rear quarter trim panel. All Vehicles 4. Remove the overhead console. 5. Remove the interior lamp lens. 6. Remove the screws and the interior lamp. 7. Remove the two sun visors. 1 Remove the six screws. 2 Remove the two sun visors. If equipped, disconnect the electrical connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9883 8. Remove the two sun visor brackets. 1 Remove the two screws. 2 Remove the two sun visor brackets. 9. Remove the six assist handle bolt covers. 10. Remove the three assist handles. 1 Remove the six bolts. 2 Remove the three assist handles. Sport Trac 11. Remove the passenger seat. NOTE: The headliner is removed through the passenger side front door. All Vehicles 12. Remove the headliner. INSTALLATION 1. To install, reverse the removal procedure Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9884 Headliner: Removal and Replacement HEADLINER Removal and Installation All Vehicles 1. Disconnect the battery ground cable. Sport Trac 2. Remove the C-pillar trim panel. Explorer Sport 3. Remove the rear quarter trim panel. All Vehicles 4. Remove the overhead console. 5. Remove the interior lamp lens. 6. Remove the screws and the interior lamp. 7. Remove the two sun visors. 1. Remove the six screws. 2. Remove the two sun visors. If equipped, disconnect the electrical connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9885 8. Remove the two sun visor brackets. 1. Remove the two screws. 2. Remove the two sun visor brackets. 9. Remove the six assist handle bolt covers. 10. Remove the three assist handles. 1. Remove the six bolts. 2. Remove the three assist handles. Sport Trac 11. NOTE: The headliner is removed through the passenger side front door. Remove the passenger seat. All Vehicles 12. Remove the headliner. 13. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures B-Pillar Trim Panel Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the windshield side garnish moulding. 2. Remove the scuff plate. 1 Starting at one end and working along the scuff plate, release the scuff plate locking tabs. 2 Remove the scuff plate. 3. Remove the coat hook. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9890 1 Remove the screw. 2 Remove the coat hook. 4. Open the front safety belt guide bolt cover. 5. Using the special tool, remove the front safety belt guide bolt. 6. Position the carpet aside. 7. Using the special tool, remove the front safety belt anchor bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9891 8. Remove the B-pillar trim panel. 1 Remove the pin-type retainer. 2 Feed the safety belt webbing through the opening. 3 Remove the B-pillar trim panel. INSTALLATION 1. To install, reverse the removal procedure. C-Pillar Trim Panel Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the B-pillar trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9892 2. Open the rear safety belt guide bolt cover. 3. Using the special tool, remove the rear safety belt guide bolt. 4. Position the carpet aside. 5. Remove the rear safety belt anchor nut. 6. Remove the roof trim panel. 7. Remove the six luggage compartment back lower trim cover screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9893 8. Remove the luggage compartment back lower trim cover. - Remove the six pin-type retainers. 9. Remove the pin-type retainer from C-pillar trim panel. 10. Remove the safety belt anchor trim cover. 11. Remove the C-pillar trim panel. - Feed the safety belt webbing through the opening. INSTALLATION 1. To install, reverse the removal procedure. Liftgate Trim Panel REMOVAL 1. Open the liftgate glass. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9894 2. Remove the liftgate handle. 1 Remove the liftgate handle screws. 2 Remove the liftgate handle. 3. Remove the liftgate trim panel screw access plug. 4. Remove the liftgate trim panel screw. 5. Remove the liftgate trim panel. 1 Remove the liftgate trim panel from the liftgate window opening. 2 Push the liftgate trim panel toward the top of the liftgate and remove the liftgate trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9895 Rear Quarter Trim Panel Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the windshield side garnish moulding. 2. Remove the scuff plate. 3. Remove the front safety belt guide bolt cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9896 4. Using the special tool, remove the front safety belt guide bolt. 5. Position the carpet aside. 6. Using the special tool, remove the front safety belt anchor bolt. 7. If equipped, remove the retractable cargo cover. 8. Remove the liftgate scuff plate. 9. Fold the rear seat into the load floor position. 10. Using the special tool, remove the rear safety belt guide bolt. 11. Position the carpet aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9897 12. Using the special tool, remove the rear safety belt anchor bolt. 13. Remove the rear quarter window latch screws. 14. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. 15. Remove the quarter trim panel front screw. - Position the carpet aside to gain access to the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9898 16. Remove the three quarter trim panel rear screws. - Position the carpet aside to gain access to the screws. 17. If equipped, remove the rear door lock control switch assembly. - Disconnect the electrical connector. 18. Remove the quarter trim panel. 1 Remove the eight pin-type retainers. 2 Feed the safety belt webbing through the opening in the quarter trim panel. 3 Remove the quarter trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9899 Trim Panel: Removal and Replacement C-Pillar Trim Panel C-PILLAR TRIM PANEL Special Tool(s) Special Tool(s) Removal and Installation 1. Remove the B-pillar trim panel. 2. Open the rear safety belt guide bolt cover. 3. Using the special tool, remove the rear safety belt guide bolt. 4. Position the carpet aside. 5. Remove the rear safety belt anchor nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9900 6. Remove the roof trim panel. 7. Remove the six luggage compartment back lower trim cover screws. 8. Remove the luggage compartment back lower trim cover. - Remove the six pin-type retainers. 9. Remove the pin-type retainer from C-pillar trim panel. 10. Remove the safety belt anchor trim cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9901 11. Remove the C-pillar trim panel. - Feed the safety belt webbing through the opening. 12. To install, reverse the removal procedure. Rear Quarter Trim Panel REAR QUARTER TRIM PANEL Special Tool(s) Special Tool(s) Removal and Installation 1. Remove the windshield side garnish moulding. 2. Remove the scuff plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9902 3. Remove the front safety belt guide bolt cover. 4. Using the special tool, remove the front safety belt guide bolt. 5. Position the carpet aside. 6. Using the special tool, remove the front safety belt anchor bolt. 7. If equipped, remove the retractable cargo cover. 8. Remove the liftgate scuff plate. 9. Fold the rear seat into the load floor position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9903 10. Using the special tool, remove the rear safety belt guide bolt. 11. Position the carpet aside. 12. Using the special tool, remove the rear safety belt anchor bolt. 13. Remove the rear quarter window latch screws. 14. Remove the coat hook. 1. Remove the screw. 2. Remove the coat hook. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9904 15. Remove the quarter trim panel front screw. - Position the carpet aside to gain access to the screw. 16. Remove the three quarter trim panel rear screws. - Position the carpet aside to gain access to the screws. 17. If equipped, remove the rear door lock control switch assembly. - Disconnect the electrical connector. 18. Remove the quarter trim panel. 1. Remove the eight pin-type retainers. 2. Feed the safety belt webbing through the opening in the quarter trim panel. 3. Remove the quarter trim panel. 19. To install, reverse the removal procedure. Trim Panel - B-Pillar B-PILLAR TRIM PANEL Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9905 Special Tool(s) Special Tool(s) Removal and Installation 1. Remove the windshield side garnish moulding. 2. Remove the scuff plate. 1. Starting at one end and working along the scuff plate, release the scuff plate locking tabs. 2. Remove the scuff plate. 3. Remove the coat hook. 1. Remove the screw. 2. Remove the coat hook. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9906 4. Open the front safety belt guide bolt cover. 5. Using the special tool, remove the front safety belt guide bolt. 6. Position the carpet aside. 7. Using the special tool, remove the front safety belt anchor bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9907 8. Remove the B-pillar trim panel. 1. Remove the pin-type retainer. 2. Feed the safety belt webbing through the opening. 3. Remove the B-pillar trim panel. 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair REMOVAL NOTE: - When a new lock cylinder is installed, both door lock cylinders, liftgate lock cylinders, tailgate and ignition lock cylinder should be installed as a set. This will eliminate carrying an extra key which will fit only one lock. If a new key is to be used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the front door trim panel. 2. Make sure the window is in the fully raised position. 3. Position the watershield aside. 4. Remove the door lock cylinder. 1 Disconnect the lock cylinder rod. 2 Remove the retaining clip. 3 Remove the door lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9918 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9919 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9920 Keyless Entry Key-Pad: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9921 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Remove the front door speaker. 2. Disconnect the keyless entry electrical connector. 3. Remove the two wiring harness locators. 4. Release the retaining clip. 5. Remove the key less entry keypad. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9927 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9928 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9929 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9930 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9931 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9932 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9933 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9934 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9935 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9936 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9937 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9938 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9939 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9940 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9941 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9942 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9943 Keyless Entry Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9944 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9945 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9946 Keyless Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9947 Keyless Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9948 Keyless Entry Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Side > Page 9954 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Side > Page 9955 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Side > Page 9956 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 9957 Power Door Lock Actuator: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Remove the door glass run channel. 1 Remove the bolt. 2 Remove the door glass run channel. Release the wiring harness locator. 4. Disconnect the door lock actuator electrical connector. 5. Remove the front door lock actuator rivet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 9958 6. Release the wiring harness locator. 7. Remove the front door lock actuator. INSTALLATION 1. To install, reverse the removal procedure. - Using the special tool, install the rivet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 9959 Heavy - Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9965 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9966 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9967 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9968 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9969 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9970 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9971 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9972 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9973 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9974 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9975 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9976 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9977 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9978 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9979 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9980 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9981 Power Door Lock Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9982 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9983 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9984 Power Door Lock Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9985 Power Door Lock Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Page 9986 Power Door Lock Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Driver Door Unlock Relay Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Driver Door Unlock Relay > Page 9991 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay > Page 9994 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay > Page 9995 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Page 9996 Power Door Lock Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Page 9997 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Side > Page 10002 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10005 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10006 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10007 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the liftgate latch remote control. 2. Remove the liftgate lock cylinder. 1 Remove the nuts. 2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 10015 Power Mirror Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 10016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Premature Clearcoat Cracking Service Tips Paint: Technical Service Bulletins Paint - Premature Clearcoat Cracking Service Tips Article No. 02-17-1 PAINT-PREMATURE CLEARCOAT CRACKING-SERVICE TIPS FORD: 1999-2002 EXPLORER 2000-2002 EXPLORER SPORT TRAC, EXPLORER SPORT MERCURY: 1999-2002 MOUNTAINEER ISSUE Some vehicles may exhibit crowsfoot or premature star cracking primarily on the hood, but could also be on other panels. This is due to high paint film build and acrylic melamine paint technology. ACTION Read this TSB in its entirety BEFORE beginning any repairs. Inspect and repair as outlined in following Service Procedures. SERVICE PROCEDURE 1999-2002 Vehicles-Dark Colors (Code LL Blue, Code UA Black, and Code SU Green only) NOTE READ THIS REPAIR PROCEDURE COMPLETELY. SUBJECT VEHICLES HAVE PAINT THICKNESS ABOVE 5.5 MILS. 1. Check paint film thickness on affected panels. NOTE IF PLASTIC MEDIA BLASTING IS BEING USED, PROCEED TO STEP 4. NOTE TECHNICIAN PERFORMING THE SANDING OPERATION SHOULD WEAR AN APPROVED RESPIRATOR WITH HIGH EFFICIENCY PARTICULATE FILTERS (HEPA). TECHNICIANS SHOULD USE A DUAL ACTION SANDER WITH VACUUM COLLECTION EQUIPMENT. THE VACUUM EQUIPMENT MUST BE EQUIPPED WITH A HEPA FILTER ON THE AIR EXHAUST. OPERATORS ARE CAUTIONED TO FOLLOW MANUFACTURERS GUIDELINES FOR MAINTENANCE OR REPLACEMENT OF THESE FILTERS. 2. Remove all clearcoat and basecoat by sanding down to the E-coat primer with 80 grit-sanding discs on a Dual Action vacuum sander. The E-coat color is Green. 3. Blow off the panel with compressed air to remove loose dust and debris. 4. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. Keep wiping until the surface is completely dry. 5. Mask off all necessary panels. Tack off the surface. 6. Mix and apply Ford Approved epoxy or self-etching primer to all bare metal areas on the panel. 7. Mix and apply 2.0 mils minimum of Ford Approved primer surfacer following the manufacturers label recommendations and bake at 140°F (60° C) panel temperature per manufacturers recommended baking time. 8. Block sand the affected panels with 600 grit sand paper. 9. Blow off the area with compressed air to remove loose dust and debris. 10. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. NOTE KEEP WIPING UNTIL THE SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY RESULT CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. 11. Mix and apply Ford Approved basecoat material following the manufacturers label recommendations and flash time. 12. Mix and apply 2.0 mils minimum of Ford Approved clearcoat and bake at 140°F (60°C) panel temperature per manufacturers recommended baking time. 13. Demask the vehicle as necessary. WARNING TO SAFEGUARD OUR ENVIRONMENT, PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (VOC) OR EXCESS MATERIALS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Premature Clearcoat Cracking Service Tips > Page 10022 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes Vehicle Certification (VC) Label, Part 1 Vehicle Certification (VC) Label, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10025 The Vehicle Certification (VC) label contains information on the manufacturer name, the month and year of manufacture, the certification statement, and the VIN. It also includes the Gross Vehicle Weight Rating (GVWR). VEHICLE CERTIFICATION LABEL REFERENCE Paint Codes The first set of code numbers list the primary body color, the second set of code numbers list the lower body or two-tone paint code (if applicable). The following lists the exterior paint codes: Primary body color codes B2 - Harvest Gold - FY - Woodland Green (clear coat) - FL - Medium Toreador Red - LL - Deep Wedgewood Blue - UA - Ebony - YZ - Oxford White - R1 - Island Blue (clear coat) - RS - Silver Frost (clear coat) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10026 Tape/Paint Stripe Code Tape or paint stripe codes do not apply. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10027 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10028 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10029 Paint: Application and ID DSO Fleet Color Codes Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10030 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10031 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Radiator Support > Component Information > Locations Radiator Support: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Radiator Support > Component Information > Locations > Page 10035 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10042 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10043 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10044 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10045 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10046 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10047 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10048 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10049 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10050 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10051 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10052 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10053 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10054 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10055 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10056 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10057 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10058 Keyless Entry Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10059 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10060 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10061 Keyless Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10062 Keyless Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 10063 Keyless Entry Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10069 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10070 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10071 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10072 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10073 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10074 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10075 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10076 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10077 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10078 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10079 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10080 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10081 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10082 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10083 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10084 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10085 Power Door Lock Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10086 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10087 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10088 Power Door Lock Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10089 Power Door Lock Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 10090 Power Door Lock Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Driver Door Unlock Relay Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Driver Door Unlock Relay > Page 10095 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay > Page 10098 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Driver Door Unlock Relay > Page 10099 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Page 10100 Power Door Lock Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Page 10101 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 10105 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair Sunroof / Moonroof Motor: Service and Repair REMOVAL 1. Close the roof opening panel. If necessary, refer to Manual Operation. 2. Position the overhead console aside. 3. Remove the roof opening panel motor. 1 Remove the bolts. 2 Remove the roof opening panel motor. Disconnect the electrical connector. NOTE: Make sure that the roof opening panel motor is in the closed position. INSTALLATION 1. Connect the roof opening panel motor electrical connector. 2. With the ignition switch on and the roof opening panel motor still removed, bump the roof opening panel switch one time only towards the close or vent position. 3. Install the roof opening panel motor. 1 Position the roof opening panel motor. 2 Install the roof opening panel bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Page 10111 4. Install the overhead console. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 10115 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Position the overhead console aside. 2. Remove the roof opening panel control switch. 1 Remove the screws. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair Sunroof / Moonroof Track: Service and Repair REMOVAL 1. Remove the headliner. 2. Disconnect the roof opening panel motor electrical connector. 3. Remove the roof opening panel frame. 1 Disconnect the four drain hoses. 2 Remove the 18 screws. 3 Remove the roof opening panel frame. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair REMOVAL 1. Open the roof opening panel to the fully retracted position. 2. Release the two air deflector arms. 3. Remove the air deflector. 1 Detach the two air deflector retainer clips from the U-frame. 2 Remove the air deflector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise Sunroof / Moonroof Frame: Customer Interest Body - Moonroof Squeak or Rattle Noise TSB 05-3-4 02/21/05 MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2005 Mountaineer ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail assembly. A new corner insert is now available to correct the condition (Figure 2). ACTION The corner inserts are located in both front corners of the moonroof track and can be accessed by cycling the moonroof glass to the full open position. The original corner insert design had snap tabs that may break off during installation, creating a rattle condition. Replace both of the original inserts and remove any broken tabs left in the track. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Open the moonroof to the full open position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 10130 2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver and inspect the snap tabs (Figures 1 and 2). 3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose debris (Figure 3). 4. Install a new corner insert on both sides (Figure 4). Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 10131 OPERATION DESCRIPTION TIME 050304A 2001-2003 Explorer Sport, 0.3Hr. 2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator: Replace Both Of The Moonroof Corner Inserts DEALER CODING CONDITION BASIC PART NO. CODE 78502B36 01 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise Sunroof / Moonroof Frame: All Technical Service Bulletins Body - Moonroof Squeak or Rattle Noise TSB 05-3-4 02/21/05 MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2005 Mountaineer ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail assembly. A new corner insert is now available to correct the condition (Figure 2). ACTION The corner inserts are located in both front corners of the moonroof track and can be accessed by cycling the moonroof glass to the full open position. The original corner insert design had snap tabs that may break off during installation, creating a rattle condition. Replace both of the original inserts and remove any broken tabs left in the track. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Open the moonroof to the full open position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 10137 2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver and inspect the snap tabs (Figures 1 and 2). 3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose debris (Figure 3). 4. Install a new corner insert on both sides (Figure 4). Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 10138 OPERATION DESCRIPTION TIME 050304A 2001-2003 Explorer Sport, 0.3Hr. 2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator: Replace Both Of The Moonroof Corner Inserts DEALER CODING CONDITION BASIC PART NO. CODE 78502B36 01 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 10142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair Sunroof / Moonroof Panel: Service and Repair REMOVAL 1. Open the roof opening panel to the vent position. 2. Remove the four lifter arm bolts. 3. From outside the vehicle, remove the roof opening panel. INSTALLATION 1. To install, reverse the removal procedure. - Check for correct alignment of the roof opening panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 10155 Power Seat Switch: Vehicle Damage Warnings CAUTION: - Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags Power Seat Switch: Testing and Inspection Except Side Air Bags Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 10158 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 10159 Power Seat Switch: Testing and Inspection With Side Air Bags Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 10160 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag Power Seat Switch: Service and Repair With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10163 connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10164 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. 8. Using the special tool, remove the safety belt buckle support bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10165 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10166 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10167 21. Disconnect the clockspring electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 26. Remove the lumbar support knob. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10168 27. Remove the rear side shield screw. 28. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 29. Unhook the side shield from the seat latch. 30. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10169 31. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS OR THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10170 1. Install the 6-way power seat switch. 1 Install the 6-way power seat switch. 2 Install the screws. 2. Install the side shield. 1 Install the side shield. 2 Install the electrical connector. 3. Hook the side shield to the seat latch. 4. Install the side shield clips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10171 5. Install the rear side shield screw. 6. Install the lumbar support knob. 7. Position the driver seat into the vehicle. Install the four seat track to floor bolts and hand-tighten them. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 8. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10172 9. Connect the driver seat side air bag and power seat (if equipped) electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. 3 Tie-strap the wire harness. 10. Connect the battery ground cable. 11. Position the driver seat rearward. 12. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 13. Tighten the driver seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 14. Move and tilt the driver seat to its highest and most forward position. 15. Tighten the driver seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. 16. Install the driver seat rear track bolt covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10173 17. Connect the safety belt warning indicator electrical connector. 18. Using the special tool, install the safety belt buckle support bolt. 19. Install the safety belt buckle support bolt cover. 20. Position the driver seat rearward. 21. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 22. Position the passenger seat forward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10174 23. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 24. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 25. Position the passenger seat rearward. 26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 27. Install the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10175 28. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 29. Connect the clockspring electrical connector at the base of the steering column. 30. Position the lower steering column opening finish panel reinforcement and install the bolts. 31. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10176 32. Position the hood release handle and install the screws. 33. Connect the battery ground cable. 34. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 35. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10177 Power Seat Switch: Service and Repair Without Side Air Bag REMOVAL 1. Remove the front seat. 2. Remove the lumbar control knob, if equipped. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. 5. Remove the front seat cushion side shield screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10178 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Remove the front seat cushion side shield. 8. Remove the 6-way power seat switch. - Remove the screws, then remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Page 10179 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect Technical Service Bulletin # 03S04S1 Date: 060401 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10189 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006. FSA VIN LIST ACTIVATED? Yes Available through the website by April 5, 2006. Owner names and addresses will be available for the additional vehicles by April 17, 2006. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10190 reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S04 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will only be used on approximately 25% of the repairs. The DOR/COR for this program is 50309. This number identifies parts ordered for this recall through the Special Service Support Center. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10191 ^ E-mail ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA #: 03804 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices1 refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This procedure involves replacement of certain seat recliner assembly attaching hardware on two different style driver seat assemblies. The driver seat will have either a stamped seat back frame or a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2. ^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner mechanism attaches to the seatback frame. See Figure 1. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10192 ^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is evident on the tubular seatback frame. See Figure 2. For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure 3. ^ Stamped Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1)1-inch spacer (spacer A) ^ Tubular Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1) LOWER bolt without thread sealer patch (bolt B) - One (1) 3/4-inch spacer (spacer B) SERVICE PROCEDURE FOR ALL AFFECTED VEHICLES WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10193 If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is being serviced, the supplemental restraint system (SRS) must be depowered. 1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim and accessories may vary from one seat to another of the same frame configuration. Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back frame. 2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio stations. 3. Position the driver seat to its full-forward position. 4. Turn the ignition switch from RUN to OFF. 5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge area and then remove the applicable airbag fuse. Refer to the following chart to determine which fuse must be removed when working on a vehicle with side air bags. 6. Disconnect the battery negative cable and wait one minute. 7. Position the driver seatback to Its full4orward position. 8. CAUTION: Take care not to damage the seatback trim cover during this step. Unhook the seatback trim cover J-clip. See Figure 4. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10194 9. Position the driver seatback to a straight-up position. See Figure 5. 10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See Figure 6. 11. Remove and discard the upper bolt. 12. Remove and discard the plastic bushing. See Figure 7. 13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3. ^ Spacer A 1-inch on STAMPED seatback frames. ^ Spacer B 3/4-Inch on TUBULAR seatback frames. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10195 Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer should be between the recliner mechanism arm and the seatback frame. See Figure 8. 14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft). 15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original position. 16. Position the driver seatback to its full4orward position. 17. Connect the seatback trim cover J-clip. 18. Position the driver seatback to its original position. ^ If the vehicle is equipped with a tubular seatback frame, go to Step 23. ^ If the vehicle is equipped with a stamped seatback frame, continue with the next step. 19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the ignition switch from OFF to RUN. 20. Install the airbag fuse and then install the fuse box cover. 21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 22. Position the driver seat to its original position and program the recorded preset radio stations. THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS. 23. Position the seat cushion side shield aside as follows: ^ Pull off the lumbar support manual adjuster knob, if equipped. ^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment). ^ GENTLY unsnap the shield from the seat frame and position the shield out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10196 24. Remove and discard the lower bolt from the recliner assembly. See Figure 9. 25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft). 26. Install the seat cushion side shield as follows: ^ Align and snap the shield into place. ^ Install the two (2) removed screws. ^ Install the lumbar support adjuster knob. 27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the ignition switch from OFF to RUN. 28. Install the airbag fuse and then install the fuse box cover. 29. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 30. Position the driver seat to its original position and program the recorded preset radio stations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10197 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10198 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10199 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect Technical Service Bulletin # 03S04S1 Date: 060401 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10205 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006. FSA VIN LIST ACTIVATED? Yes Available through the website by April 5, 2006. Owner names and addresses will be available for the additional vehicles by April 17, 2006. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10206 reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S04 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will only be used on approximately 25% of the repairs. The DOR/COR for this program is 50309. This number identifies parts ordered for this recall through the Special Service Support Center. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10207 ^ E-mail ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA #: 03804 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices1 refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This procedure involves replacement of certain seat recliner assembly attaching hardware on two different style driver seat assemblies. The driver seat will have either a stamped seat back frame or a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2. ^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner mechanism attaches to the seatback frame. See Figure 1. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10208 ^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is evident on the tubular seatback frame. See Figure 2. For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure 3. ^ Stamped Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1)1-inch spacer (spacer A) ^ Tubular Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1) LOWER bolt without thread sealer patch (bolt B) - One (1) 3/4-inch spacer (spacer B) SERVICE PROCEDURE FOR ALL AFFECTED VEHICLES WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10209 If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is being serviced, the supplemental restraint system (SRS) must be depowered. 1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim and accessories may vary from one seat to another of the same frame configuration. Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back frame. 2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio stations. 3. Position the driver seat to its full-forward position. 4. Turn the ignition switch from RUN to OFF. 5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge area and then remove the applicable airbag fuse. Refer to the following chart to determine which fuse must be removed when working on a vehicle with side air bags. 6. Disconnect the battery negative cable and wait one minute. 7. Position the driver seatback to Its full4orward position. 8. CAUTION: Take care not to damage the seatback trim cover during this step. Unhook the seatback trim cover J-clip. See Figure 4. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10210 9. Position the driver seatback to a straight-up position. See Figure 5. 10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See Figure 6. 11. Remove and discard the upper bolt. 12. Remove and discard the plastic bushing. See Figure 7. 13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3. ^ Spacer A 1-inch on STAMPED seatback frames. ^ Spacer B 3/4-Inch on TUBULAR seatback frames. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10211 Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer should be between the recliner mechanism arm and the seatback frame. See Figure 8. 14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft). 15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original position. 16. Position the driver seatback to its full4orward position. 17. Connect the seatback trim cover J-clip. 18. Position the driver seatback to its original position. ^ If the vehicle is equipped with a tubular seatback frame, go to Step 23. ^ If the vehicle is equipped with a stamped seatback frame, continue with the next step. 19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the ignition switch from OFF to RUN. 20. Install the airbag fuse and then install the fuse box cover. 21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 22. Position the driver seat to its original position and program the recorded preset radio stations. THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS. 23. Position the seat cushion side shield aside as follows: ^ Pull off the lumbar support manual adjuster knob, if equipped. ^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment). ^ GENTLY unsnap the shield from the seat frame and position the shield out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10212 24. Remove and discard the lower bolt from the recliner assembly. See Figure 9. 25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft). 26. Install the seat cushion side shield as follows: ^ Align and snap the shield into place. ^ Install the two (2) removed screws. ^ Install the lumbar support adjuster knob. 27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the ignition switch from OFF to RUN. 28. Install the airbag fuse and then install the fuse box cover. 29. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 30. Position the driver seat to its original position and program the recorded preset radio stations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10213 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10214 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10215 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information Seat Cushion: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET 8 LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information > Page 10220 Seat Cushion: Vehicle Damage Warnings CAUTION: - Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. - Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. - The flex mat J-clips must be Installed with the openings facing down or the seat cushion may be damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation Seat Cushion: Service and Repair Removal And Installation With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET 8 LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10223 connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10224 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. 8. Using the special tool, remove the safety belt buckle support bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10225 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 13. Remove the tie strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10226 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10227 21. Disconnect the clockspring electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 26. Remove the seat track. 27. Remove the seat backrest. INSTALLATION WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10228 - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat Systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the seat backrest. 2. Install the seat track. 3. Position the driver seat into the vehicle. Install all the seat track to floor bolts and hand-tighten them. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Connect the driver seat side air bag and power seat (if equipped) electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10229 3 Tie-strap the wire harness. 6. Connect the battery ground cable. 7. Position the driver seat rearward. 8. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 9. Tighten the driver seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 10. Move and tilt the driver seat to its highest and most forward position. 11. Tighten the driver seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. 12. Install the driver seat rear track bolt covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10230 13. Connect the safety belt warning indicator electrical connector. 14. Using the special tool, install the safety belt buckle support bolt. 15. Install the safety belt buckle support bolt cover. 16. Position the driver seat rearward. 17. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 18. Position the passenger seat forward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10231 19. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 21. Position the passenger seat rearward. 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 23. Install the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10232 24. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 25. Connect the clockspring electrical connector at the base of the steering column. 26. Position the lower steering column opening finish panel reinforcement and install the bolts. 27. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10233 28. Position the hood release handle and install the screws. 29. Connect the battery ground cable. 30. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 31. Check the restraint system for correct operation. Without Side Air Bag REMOVAL 1. Remove the seat. 2. Remove the seat track. 3. Remove the seat backrest. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10234 WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the passenger seat rearward. 2. Remove the passenger seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10235 PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 6. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10236 8. Using the special tool, remove the safety belt buckle support bolt. 9. Remove the passenger seat rear bolt trim covers. 10. Remove the passenger seat rear bolts. 11. Remove the passenger seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10237 14. Connect the battery ground cable. 15. Position the driver seat rearward. 16. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 17. Remove the retaining screws and position the hood release handle out of the way. 18. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 19. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10238 20. Disconnect the clockspring electrical connector at the base of the steering column. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 22. Remove the passenger air bag module. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 24. Connect the battery ground cable. 25. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 26. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 27. Remove the seat track. 28. Remove the seat backrest. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10239 WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the seat backrest. 2. Install the seat track. 3. Position the passenger seat into the vehicle. Install and hand-tighten the four seat track to floor bolts. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 4. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10240 5. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 6. Connect the battery ground cable. 7. Position the front seats rearward. 8. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 9. Tighten the passenger seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 10. Move and tilt the front seats to their highest and most forward position. 11. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 12. Tighten the passenger seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10241 13. Install the passenger seat rear track bolt covers. 14. Using the special tool, install the safety belt buckle support bolt. 15. Install the safety belt buckle support bolt cover. 16. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10242 17. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 18. Connect the battery ground cable. 19. Position the front seats rearward. 20. Disconnect the battery ground cable and wait at least one minute. 21. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the clockspring electrical connector at the base of the steering column. 23. Position the lower steering column opening finish panel reinforcement and install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10243 24. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 25. Position the hood release handle and install the screws. 26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 27. Install the passenger air bag module. 28. Connect the battery ground cable. 29. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 30. Check the restraint system for correct operation. Without Side Air Bag REMOVAL 1. Remove the seat. 2. Remove the seat track. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10244 3. Remove the seat backrest. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. 40 Percent Portion of 60/40 Split Bench REMOVAL 1. Remove the seat. 2. Remove the seat backrest. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. 50/50 Split Bench REMOVAL 1. Fold the rear seat cushion assembly forward. 2. Remove the retaining nut from the end of the link arm and slide the link arm from the stud on the seat cushion frame. 3. Return the seat back assembly to the upright position. 4. Remove the retaining nuts from the front floor attachment. 5. Remove the seat cushion assembly from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. 60 Percent Portion of 60/40 Split Bench REMOVAL 1. Remove the seat. 2. Remove the seat backrest. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10245 Seat Cushion: Service and Repair Disassembly and Assembly Manual, With E-Z Entry DISASSEMBLY 1. Remove the seat cushion. 2. Disconnect the seat cushion trim cover J-clips. 3. Remove the seat cushion trim cover. - Disconnect the seat trim cover from the hook and loop strips. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 4. Remove the seat cushion. - Disconnect the front and rear J-clips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10246 5. Remove the flexilator. 1 Remove the flexilator to frame springs. 2 Remove the flexilator. ASSEMBLY 1. Install the flexilator. 1 Position the flexilator. 2 Install the flexilator to frame springs. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. 3. Connect the seat cushion trim cover J-clips. 4. Install the seat cushion. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10247 Driver Side Special Tool(s) SPECIAL TOOL(S) DISASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10248 connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10249 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. 8. Using the special tool, remove the safety belt buckle support bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10250 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. 13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10251 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10252 21. Disconnect the clockspring electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 26. Remove the seat cushion. 27. Disconnect the seat cushion trim cover J-clips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10253 28. Remove the seat cushion frame from the seat cushion foam. 29. Invert the seat cushion trim cover. 30. Remove the swing rods. 1 Remove and discard the hog rings. 2 Remove the swing rods. 31. Remove the seat cushion trim cover. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 32. Remove the wire harness from the seat cushion frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10254 ASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the wire harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10255 2. Position the seat cushion trim cover. NOTE: When installing a new seat cushion trim cover, it may be necessary to cut a hole for the front seat back pad adjusting cable and the side air bag wiring harness. Use the old seat cushion trim cover as a guide for the location of the hole. 3. Install the seat cushion swing rods. 1 Position the swing rods. NOTE: Make sure the ends of the swing rods are positioned beneath the listing wires at the rear of the seat cushion foam. 2 Install the hog rings. 4. Invert the seat cushion trim cover. 5. Connect the seat cushion trim cover J-clips. 6. Install the seat cushion. 7. Position the driver seat into the vehicle. Install all the seat track to floor bolts and hand-tighten them. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10256 8. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Connect the driver seat side air bag and power seat (if equipped) electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. 3 Tie-strap the wire harness. 10. Connect the battery ground cable. 11. Position the driver seat rearward. 12. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 13. Tighten in the sequence shown the driver seat front track to floor bolts. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 14. Move and tilt the driver seat to its highest and most forward position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10257 15. Tighten in the sequence shown the driver seat rear track to floor bolts. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. 16. Install the driver seat rear track bolt covers. 17. Connect the safety belt warning indicator electrical connector. 18. Using the special tool, install the safety belt buckle support bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10258 19. Install the safety belt buckle support bolt cover. 20. Position the driver seat rearward. 21. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 22. Position the passenger seat forward. 23. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 24. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10259 25. Position the passenger seat rearward. 26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 27. Install the passenger air bag module. 28. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 29. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10260 30. Position the lower steering column opening finish panel reinforcement and install the bolts. 31. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the instrument panel. Push in the top of the lower steering column opening finish panel to seat the retaining clips. 2 Install the screws. 32. Position the hood release handle and install the screws. 33. Connect the battery ground cable. 34. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 35. Check the restraint system for correct operation. Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10261 Special Tool(s) SPECIAL TOOL(S) DISASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10262 seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the passenger seat rearward. 2. Remove the passenger seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10263 6. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. 8. Using the special tool, remove the safety belt buckle support bolt. 9. Remove the passenger seat rear bolt trim covers. 10. Remove the passenger seat rear bolts. 11. Remove the passenger seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10264 12. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 13. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 14. Connect the battery ground cable. 15. Position the driver seat rearward. 16. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 17. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10265 18. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 19. Remove the bolts and remove the lower steering column opening finish panel reinforcement. 20. Disconnect the clockspring electrical connector at the base of the steering column. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 22. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10266 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 24. Connect the battery ground cable. 25. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 26. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 27. Remove the seat cushion. 28. Disconnect the seat cushion trim cover J-clips. 29. Remove the seat cushion frame from the seat cushion foam. 30. Invert the seat cushion trim cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10267 31. Remove the swing rods. 1 Remove and discard the hog rings. 2 Remove the swing rods. 32. Remove the seat cushion trim cover. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 33. Remove the wire harness from the seat cushion frame. ASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10268 WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the wire harness. 2. Position the seat cushion trim cover. NOTE: When installing a new seat cushion trim cover, it may be necessary to cut a hole for the front seat back pad adjusting cable and the side air bag wiring harness. Use the old seat cushion trim cover as a guide for the location of the hole. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10269 3. Install the seat cushion swing rods. 1 Position the swing rods. NOTE: Make sure the ends of the swing rods are positioned beneath the listing wires at the rear of the seat cushion foam. 2 Install the hog rings. 4. Invert the seat cushion trim cover. 5. Position the seat cushion foam to the seat cushion frame. 6. Connect the seat cushion trim cover J-clips. 7. Install the seat cushion. 8. Position the passenger seat into the vehicle. Install and hand-tighten the four seat track to floor bolts. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10270 9. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 11. Connect the battery ground cable. 12. Position the front seats rearward. 13. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 14. Tighten the passenger seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 15. Move and tilt the front seats to their highest and most forward position. 16. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10271 TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 17. Tighten the passenger seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. 18. Install the passenger seat rear track bolt covers. 19. Using the special tool, install the safety belt buckle support bolt. 20. Install the safety belt buckle support bolt cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10272 21. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 23. Connect the battery ground cable. 24. Position the front seats rearward. 25. Disconnect the battery ground cable and wait at least one minute. 26. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10273 27. Connect the clockspring electrical connector at the base of the steering column. 28. Position the lower steering column opening finish panel reinforcement and install the bolts. 29. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 30. Position the hood release handle and install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10274 31. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 32. Install the passenger air bag module. 33. Connect the battery ground cable. 34. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 35. Check the restraint system for correct operation. Without Side Air Bag DISASSEMBLY 1. Remove the seat. 2. Remove the seat cushion. 3. Disconnect the seat backrest recliner actuator. 1 Remove the screws. 2 Disconnect the seat backrest recliner actuator. 4. Remove the seat cushion frame from the seat cushion foam. 1 Unhook the seat cushion trim cover J-clips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10275 2 Remove the seat cushion frame from the seat cushion foam. 5. Remove the seat cushion foam from the seat cushion frame. 6. Invert the seat cushion trim cover. 7. Remove the swing rod to tie-down wire hog rings from the side swing rods (one on each side). 8. Remove and discard the hog rings. 1 Fold back the seat cushion trim cover to expose the hog rings. 2 Remove and discard the hog rings on the front and side trenches. NOTE: The hog rings along the front of the seat are shown, the hog rings along either side are similar. 9. Remove the swing rods. 10. Remove the power seat wiring harness. 1 Disconnect the pin-type retainers. 2 Remove the power seat wiring harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10276 11. Remove the flexilator. 1 Remove the flexilator springs. 2 Remove the flexilator. 12. Remove the seat backrest recliner roll pins and remove the seat backrest recliners. 13. Disconnect the seat backrest recliners from the seat backrest recliner actuator. 1 Disconnect the seat backrest recliner actuator cable housings from the seat backrest recliners. 2 Unhook the seat backrest recliner actuator cables from the seat backrest recliners. ASSEMBLY 1. Connect the seat backrest recliners to the seat backrest recliner actuator. 1 Hook the seat backrest recliner actuator cables to the seat backrest recliners. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10277 2 Connect the seat backrest recliner actuator cable housings to the seat backrest recliners. 2. Install the seat backrest recliner roll pins. 3. Install the flexilator. 1 Position the flexilator. 2 Install the flexilator springs. 4. Install the power seat wiring harness. 1 Position the power seat wiring harness. 2 Install the pin-type retainers. 5. Install the front swing rod. 6. Install the swing rods. NOTE: Make sure the swing rods are seated under the boarder wire in the foam near the back of the seat cushion. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10278 7. Install the hog rings. 1 Fold back the seat cushion trim cover to the hog ring installation position. 2 Hog ring the center of the front swing rod to the tie-down rod in the seat cushion. 3 Hog ring the front swing rod to tie-down wire outboard sides. NOTE: The hog rings along the front of the seat are shown; the hog rings along either side are similar. 8. Hog ring the side swing rods (one on each side) to the tie-down wire. 9. Invert the seat cushion trim cover. 10. Set the hook and loop fasteners. 11. Install the seat cushion foam to the seat cushion frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10279 12. Install the seat cushion frame. 1 Position the seat cushion frame. 2 Hook the seat cushion trim cover J-clips. 13. Connect the seat backrest recliner actuator. 1 Connect the seat backrest recliner actuator. 2 Install the screws. Tighten until the screws are fully seated. 14. Install the seat cushion. 15. Install the seat. 16. Check the restraint system for correct operation 40 Percent Portion of 60/40 Split Bench DISASSEMBLY 1. Remove the rear seat. 2. Remove the rear seat legs. 1 Remove the pivot bolts. 2 Remove the rear seat legs. 3. Unhook the seat cushion trim cover J-clips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10280 4. Remove the seat cushion trim cover. - Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 5. Remove the seat cushion flex mat. 1 Unhook the rear flex mat J-clip. 2 Unhook the front flex mat J-clip. 3 Remove the seat cushion flex mat. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the rear flex mat J-clip. ASSEMBLY 1. Install the seat cushion flex mat. 1 Position the seat cushion flex mat. 2 Rook the front flex mat J-clip. 3 Hook the rear flex mat J-clip. CAUTION: The flex mat J-clips must be Installed with the openings facing down or the seat cushion may be damaged. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the rear flex mat J-clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10281 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. 3. Hook the seat cushion trim cover J-clips. 4. Install the rear seat riser pivot bolts. 1 Position the rear seat legs. 2 Install the rear seat riser pivot bolts. 5. Install the seat. NOTE: Check the restraint system for correct operation. 50/50 Split Bench DISASSEMBLY Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10282 1. Remove the pivot legs. 1 Remove the bolts. 2 Remove the pivot legs. 2. Remove the seat cushion trim cover. - Disconnect the pin-type retainers. 3. Remove the seat cushion foam from the seat cushion frame. ASSEMBLY 1. To assemble, reverse the disassembly procedure. NOTE: Check the restraint system for correct operation. 60 Percent Portion of 60/40 Split Bench DISASSEMBLY 1. Remove the seat. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10283 2. Remove the seat cushion legs. 1 Remove the pivot bolts. 2 Remove the seat cushion legs. 3. Remove the seat cushion frame from the seat cushion foam. 1 Unhook the seat cushion trim cover J-clips. 2 Remove the seat cushion frame from the seat cushion foam. 4. Invert the seat cushion trim cover. 5. Remove the seat cushion trim cover. - Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10284 6. Remove the seat cushion flex mats. 1 Unhook the rear flex mat J-clips. 2 Unhook the front flex mat J-clips. 3 Remove the seat cushion flex mats. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the rear flex mat J-clip. ASSEMBLY 1. Install the seat cushion flex mats. 1 Position the seat cushion flex mats. 2 Hook the front flex mat J-clips. 3 Hook the rear flex mat J-clips. CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion foam may be damaged. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the rear flex mat clip. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 10285 3. Install the seat cushion frame into the seat cushion foam. 1 Position the seat cushion frame. 2 Hook the seat cushion trim cover J-clips. 4. Install the seat cushion legs. 1 Position the seat cushion legs. 2 Install the rear seat riser pivot bolts. 5. Install the seat. NOTE: Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions > Technician Safety Information Seat Track: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions > Technician Safety Information > Page 10290 Seat Track: Vehicle Damage Warnings CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry Seat Track: Service and Repair E-Z Entry REMOVAL 1. Remove the front seat. 2. Remove the safety belt buckle support. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support. 3. Unfasten the seat backrest spring clip. 4. Remove the seat track to seat cushion front bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10293 5. Remove the front seat track. 1 Remove the seat track to seat cushion rear bolts. 2 Remove the front seat track. INSTALLATION 1. Install the front seat track front bolts. 1 Position the front seat track. 2 Install the inboard bolt. 3 Install the outboard bolt. 2. Install the front seat track rear bolts. 1 Install the inboard bolt. 2 Install the outboard bolt. 3. Fasten the seat backrest spring clips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10294 4. Install the safety belt buckle support onto the slide bar. 1 Position the safety belt buckle support onto the slide bar. 2 Using the special tool, install the safety belt buckle support bolt. 3 Remove the safety belt buckle support from the vise. 5. Install the safety belt buckle slide bar onto the seat. 1 Position the safety belt buckle slide bar to the seat. 2 Install the nut and bolt. 6. Install the front seat. 7. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10295 Seat Track: Service and Repair Front Manual REMOVAL 1. Remove the front seat. 2. Remove the safety belt buckle support. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support. 3. Remove the seat track to seat cushion front bolts. 4. Remove the front seat track. 1 Remove the seat track to seat cushion rear bolts. 2 Remove the front seat track. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10296 1. Install the front seat track front bolts. 1 Position the front seat track. 2 Install the inboard bolt. 3 Install the outboard bolt. 2. Install the front seat track rear bolts. 1 Install the inboard bolt. 2 Install the outboard bolt. 3. Install the safety belt buckle support onto the slide bar. 1 Position the safety belt buckle support onto the slide bar. 2 Using the special tool, install the safety belt buckle support bolt. 3 Remove the safety belt buckle support from the vise. 4. Install the safety belt buckle slide bar onto the seat. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10297 1 Position the safety belt buckle slide bar to the seat. 2 Install the nut and bolt. 5. Install the front seat. 6. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10298 Seat Track: Service and Repair Front Power With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10299 connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat Systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10300 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. 8. Using the special tool, remove the safety belt buckle support bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10301 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10302 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10303 21. Disconnect the clockspring electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 26. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 27. Remove the safety belt buckle support. 1 Remove the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10304 2 Remove the bolt. 3 Remove the safety belt buckle support. 28. Disconnect the seat track wiring harness electrical connector. 29. Remove the seat track. 1 Remove the bolts. 2 Remove the seat track. INSTALLATION WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10305 - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the seat track. NOTE: When installing the power seat track, start at the corner with the round hole and work around the seat base in a horseshoe pattern. 2. Connect the seat track wiring harness electrical connectors. 3. Install the safety belt buckle support onto the slide bar. 1 Position the safety belt buckle support onto the slide bar. 2 Using the special tool, install the safety belt buckle support bolt. 3 Remove the safety belt buckle support from the vise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10306 4. Install the safety belt buckle slide bar onto the seat. 1 Position the safety belt buckle slide bar to the seat. 2 Install the nut and bolt. 5. Position the driver seat into the vehicle. Install all the seat track to floor bolts and hand-tighten them. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 6. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Connect the driver seat side air bag and power seat (if equipped) electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. 3 Tie-strap the wire harness. 8. Connect the battery ground cable. 9. Position the driver seat rearward. 10. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10307 11. Tighten the driver seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 12. Move and tilt the driver seat to its highest and most forward position. 13. Tighten the driver seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. 14. Install the driver seat rear track bolt covers. 15. Connect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10308 16. Using the special tool, install the safety belt buckle support bolt. 17. Install the safety belt buckle support bolt cover. 18. Position the driver seat rearward. 19. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 20. Position the passenger seat forward. 21. Remove the restraint system diagnostic tool from the passenger seat side airbag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOLS IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10309 22. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 23. Position the passenger seat rearward. 24. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 25. Install the passenger air bag module. 26. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10310 27. Connect the clockspring electrical connector at the base of the steering column. 28. Position the lower steering column opening finish panel reinforcement and install the bolts. 29. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 30. Position the hood release handle and install the screws. 31. Connect the battery ground cable. 32. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10311 33. Check the restraint system for correct operation. Without Side Air Bag Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag delete resistor electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10312 6. Remove the safety belt buckle support bolt cover plug. 7. Using the special tool, remove the safety belt buckle support bolt. 8. Disconnect the safety belt warning indicator electrical connector. 9. Remove the driver seat rear bolt trim covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10313 10. Remove the driver seat rear bolts. 11. Remove the driver seat from the vehicle. 12. Remove the safety belt buckle support. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support. 13. Disconnect the seat track wiring harness electrical connector. 14. Remove the seat track. 1 Remove the bolts. 2 Remove the seat track. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10314 1. Install the seat track. NOTE: When installing the power seat track, start at the corner with the round hole and work around the seat base in a horseshoe pattern. 2. Connect the seat track wiring harness electrical connectors. 3. Install the safety belt buckle support onto the slide bar. 1 Position the safety belt buckle support onto the slide bar. 2 Using the special tool, install the safety belt buckle support bolt. 3 Remove the safety belt buckle support from the vise. 4. Install the safety belt buckle slide bar onto the seat. 1 Position the safety belt buckle slide bar to the seat. 2 Install the nut and bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10315 5. Position the driver seat into the vehicle. Install all the seat track to floor bolts and hand-tighten them. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 6. Connect the driver seat side air bag delete resistor and power seat electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag delete resistor electrical connector. 3 Tie-strap the wire harness. 7. Connect the battery ground cable. 8. Position the driver seat rearward. 9. Tighten the driver seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 10. Move and tilt the driver seat to its highest and most forward position. 11. Tighten the driver seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > E-Z Entry > Page 10316 12. Install the driver seat rear track bolt covers. 13. Connect the safety belt warning indicator electrical connector. 14. Using the special tool, install the safety belt buckle support bolt. 15. Install the safety belt buckle support bolt cover. 16. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 10317 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 10324 OASIS CODES: 201000, 201200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Side > Page 10329 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10332 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10333 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 10334 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 10338 Power Mirror Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 10339 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 10345 Power Seat Switch: Vehicle Damage Warnings CAUTION: - Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags Power Seat Switch: Testing and Inspection Except Side Air Bags Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 10348 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 10349 Power Seat Switch: Testing and Inspection With Side Air Bags Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Except Side Air Bags > Page 10350 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag Power Seat Switch: Service and Repair With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10353 connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the driver seat rearward. 2. Remove the driver seat front track to floor bolts. 3. Move and tilt the front seats to their highest and most forward position. 4. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 5. Disconnect the driver seat. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag electrical connector. 3 Disconnect the driver seat power seat track electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10354 6. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. 7. Remove the safety belt buckle support bolt cover plug. 8. Using the special tool, remove the safety belt buckle support bolt. 9. Disconnect the safety belt warning indicator electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10355 10. Remove the driver seat rear bolt trim covers. 11. Remove the driver seat rear bolts. 12. Remove the driver seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 13. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 14. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 15. Position the passenger seat rearward. 16. Remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10356 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. 18. Remove the retaining screws and position the hood release handle out of the way. 19. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 20. Remove the bolts and remove the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10357 21. Disconnect the clockspring electrical connector at the base of the steering column. 22. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. 23. Connect the battery ground cable. 24. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. 25. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 26. Remove the lumbar support knob. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10358 27. Remove the rear side shield screw. 28. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 29. Unhook the side shield from the seat latch. 30. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10359 31. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS OR THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Refer to Air Bag Systems. - Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. - After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10360 1. Install the 6-way power seat switch. 1 Install the 6-way power seat switch. 2 Install the screws. 2. Install the side shield. 1 Install the side shield. 2 Install the electrical connector. 3. Hook the side shield to the seat latch. 4. Install the side shield clips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10361 5. Install the rear side shield screw. 6. Install the lumbar support knob. 7. Position the driver seat into the vehicle. Install the four seat track to floor bolts and hand-tighten them. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 8. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10362 9. Connect the driver seat side air bag and power seat (if equipped) electrical connectors. 1 Connect the driver seat power seat track electrical connector. 2 Connect the driver seat side air bag electrical connector. 3 Tie-strap the wire harness. 10. Connect the battery ground cable. 11. Position the driver seat rearward. 12. With the restraint system diagnostic tools still in place at the remaining deployable devices, prove out the air bag system. 13. Tighten the driver seat front track to floor bolts in the sequence shown. 1 Tighten the front inboard bolt. 2 Tighten the front outboard bolt. 14. Move and tilt the driver seat to its highest and most forward position. 15. Tighten the driver seat rear track to floor bolts in the sequence shown. 1 Tighten the rear inboard bolt. 2 Tighten the rear outboard bolt. 16. Install the driver seat rear track bolt covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10363 17. Connect the safety belt warning indicator electrical connector. 18. Using the special tool, install the safety belt buckle support bolt. 19. Install the safety belt buckle support bolt cover. 20. Position the driver seat rearward. 21. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE WORK WORKSHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 22. Position the passenger seat forward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10364 23. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 24. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. 25. Position the passenger seat rearward. 26. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 27. Install the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10365 28. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 29. Connect the clockspring electrical connector at the base of the steering column. 30. Position the lower steering column opening finish panel reinforcement and install the bolts. 31. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10366 32. Position the hood release handle and install the screws. 33. Connect the battery ground cable. 34. With all the diagnostic tools removed, prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 35. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10367 Power Seat Switch: Service and Repair Without Side Air Bag REMOVAL 1. Remove the front seat. 2. Remove the lumbar control knob, if equipped. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. 5. Remove the front seat cushion side shield screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > With Side Air Bag > Page 10368 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Remove the front seat cushion side shield. 8. Remove the 6-way power seat switch. - Remove the screws, then remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Page 10369 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 10373 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Position the overhead console aside. 2. Remove the roof opening panel control switch. 1 Remove the screws. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Ajar Switch Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10378 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 10379 Trunk / Liftgate Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 10380 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is installed: - under the hood. - above and below the instrument panel. - at the A-pillar lower trim panel. - over the front and rear tunnel. - over the front and rear floor pans. - inside the B-pillar. - inside the C-pillar. - inside the D-pillar (Explorer Sport). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition Tailgate Hinge: Customer Interest Tailgate - Squeaking/Binding Condition Article No. 02-3-5 02/18/02 ^ BODY - "SQUEAK" OR BIND FROM TAILGATE ^ NOISE - "SQUEAK" OR BIND FROM TAILGATE FORD: 1997-1998 F SUPER DUTY 1997-2002 F-150, RANGER 1999-2002 SUPER DUTY F SERIES 2001-2002 EXPLORER SPORT TRAC ISSUE Some vehicles may exhibit a "Squeak" or Bind condition of the Tailgate. This may be caused by the grease on the tailgate hinges that may wash out prematurely causing a squeak or binding condition. ACTION Verify condition. Apply Silicone grease to correct the condition. Refer the the following Service Procedure for details. SERVICE PROCEDURE 1. Remove tail gate from the vehicle. 2. Remove plastic inserts from tail gate hinge cups. 3. Clean inside of hinge cups. 4. Apply grease (use only XG-3), to all inside surfaces of right and left side hinge cups and right and left side body side pins (Figure 1) and re-install plastic inserts into tail gate. 5. Reinstall the tail gate Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition > Page 10393 Parts Block OTHER APPLICABLE ARTICLES: NONE OPERATION DESCRIPTION TIME 020305A Apply Grease As 0.3 Hr. Instructed In Service Procedure DEALER CODING CONDITION BASIC PART NO. CODE 99430B22 41 OASIS CODES: 111000,112600, 702000, 702200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition Tailgate Hinge: All Technical Service Bulletins Tailgate - Squeaking/Binding Condition Article No. 02-3-5 02/18/02 ^ BODY - "SQUEAK" OR BIND FROM TAILGATE ^ NOISE - "SQUEAK" OR BIND FROM TAILGATE FORD: 1997-1998 F SUPER DUTY 1997-2002 F-150, RANGER 1999-2002 SUPER DUTY F SERIES 2001-2002 EXPLORER SPORT TRAC ISSUE Some vehicles may exhibit a "Squeak" or Bind condition of the Tailgate. This may be caused by the grease on the tailgate hinges that may wash out prematurely causing a squeak or binding condition. ACTION Verify condition. Apply Silicone grease to correct the condition. Refer the the following Service Procedure for details. SERVICE PROCEDURE 1. Remove tail gate from the vehicle. 2. Remove plastic inserts from tail gate hinge cups. 3. Clean inside of hinge cups. 4. Apply grease (use only XG-3), to all inside surfaces of right and left side hinge cups and right and left side body side pins (Figure 1) and re-install plastic inserts into tail gate. 5. Reinstall the tail gate Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition > Page 10399 Parts Block OTHER APPLICABLE ARTICLES: NONE OPERATION DESCRIPTION TIME 020305A Apply Grease As 0.3 Hr. Instructed In Service Procedure DEALER CODING CONDITION BASIC PART NO. CODE 99430B22 41 OASIS CODES: 111000,112600, 702000, 702200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch Tailgate Latch: Service and Repair Tailgate Latch REMOVAL 1. Remove the tailgate trim panel. 1 Remove the screws. 2 Remove the pin-type retainers. 2. Remove the tailgate latch bolts. 3. Remove the tailgate latch actuating rod guide. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 10404 4. Remove the tailgate latch. 1 Release the actuating rod. 2 Remove the tailgate latch. INSTALLATION 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 10405 Tailgate Latch: Service and Repair Tailgate Latch Remote Control REMOVAL 1. Remove the tailgate trim panel. 1 Remove the screws. 2 Remove the pin-type retainers 2. Release the tailgate latch actuating rods from the remote control. NOTE: Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. 3. Remove the tailgate latch remote control nuts. 4. Remove the tailgate latch remote control. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 10406 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Service and Repair Tailgate Lock Cylinder: Service and Repair REMOVAL 1. Remove the tailgate release handle. 2. Remove the clip and the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair REMOVAL 1. Remove the tailgate trim panel. 1 Remove the screws. 2 Remove the pin-type retainers. 2. Disconnect the tailgate latch actuating rods from the remote control. 1 Open the clips. 2 Disconnect the tailgate latch actuating rods. 3. Remove the tailgate latch remote control nuts. 4. Remove the tailgate latch release handle. - Transfer parts as necessary. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Page 10413 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Technical Service Bulletins > Body Bed Extender Component Replacement Tips Truck Bed: Technical Service Bulletins Body - Bed Extender Component Replacement Tips Article No. 03-23-5 11/24/03 BODY - BED EXTENDER - COMPONENT REPLACEMENT-SERVICE TIP FORD: 2001-2004 EXPLORER SPORT TRAC, F-150, RANGER ISSUE If service should become necessary on a bed extender, separate components are available which enable repairs without replacement of the entire unit. Replacing the entire bed extender assembly, when it is only necessary to replace the affected component(s), is considered an over repair. ACTION Prior to replacing an entire bed extender assembly, examine it closely and determine if repairs can be made utilizing the components and replacement instructions listed in this TSB. Determine also whether the complaint condition may be the result of an impact or customer abuse, as repairs for these reasons may not be covered under warranty. Refer to the following service procedures. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Technical Service Bulletins > Body Bed Extender Component Replacement Tips > Page 10418 NOTE THE ATTACHED ILLUSTRATION (FIGURE 1) SHOWS THE BED EXTENDER IN ITS DEPLOYED POSITION EXTENDED OVER THE TAILGATE. REFERENCES TO "UPPER OR LOWER", IN THE FOLLOWING PROCEDURES RELATE TO THE BED EXTENDER IN THE DEPLOYED POSITION. SERVICE PROCEDURE The service procedures below relate to the illustration part identification and the item list of Ford service parts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Technical Service Bulletins > Body Bed Extender Component Replacement Tips > Page 10419 BED EXTENDER PIN LOCK ASSEMBLY REPLACEMENT 1. Remove bed extender from vehicle. 2. Remove metal nut that retains the pin assembly to the upper tube support. 3. Slide pin assembly out of tube support. 4. Install new pin assembly to upper tube support. 5. Install retaining nut and torque to 3-4 N.m (26-35 lb-in). 6. Reinstall bed extender. BED EXTENDER SUPPORT & BRACKET TUBE ASSEMBLY REPLACEMENT 1. Remove bed extender from vehicle. 2. Remove three (3) tube caps from stainless tubes on side of issue. Save for reinstallation, Step 7. 3. Remove pin assembly by removing metal nut. 4. Remove two (2) screws attaching support to tubes. 5. Use soft hammer to tap support off tubes. 6. Slide new support over tubes, use soft hammer if needed. 7. Reinstall tube caps. 8. Note position of latching side of support, must face the pivot pin. 9. Attach new support with two (2) screws and nuts, torque to 4-5 N.m (35-44 lb-in). 10. Insert pin assembly through upper support hole. 11. Attach to support with metal nut torque to 3-4 N.m (26-35 lb-in). BED EXTENDER RUBBER BUMPER REPLACEMENT 1. Remove the four (4) screws that attach the tube support using T-25 Torx driver. 2. Note bumper position (facing up or down with extender deployed). 3. Separate the two (2) halves of the support and remove bumper. 4. Insert new bumper into cavity formed by the two (2) support halves. 5. Position the two (2) halves onto the tube with new bumper trapped by supports. 6. Install support halves to the tube with screws and nuts. 7. Torque for screws is 4-5 N.m (35-44 lb-in). Parts Block Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Technical Service Bulletins > Body Bed Extender Component Replacement Tips > Page 10420 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032305A Replace Lock Pin(S) 0.2 Hr. (Includes Time To Remove And Install Bed Extender) 032305B Replace Support and 0.3 Hr. Bracket Assembly (One Side) (Includes Time To Remove And Install Bed Extender And Replace Pin Assembly If Necessary) 032305C Replace Support and 0.4 Hr. Bracket Assemblies (Both Sides) (Includes Time To Remove And Install Bed Extender And Replace Pin Assembly If Necessary) 032305D Replace Rubber Bumpers 0.3 Hr. (Any Two) 032305E Replace Rubber Bumpers 0.5 Hr. (All) DEALER CODING CONDITION BASIC PART NO. CODE 99286A40 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Technical Service Bulletins > Page 10421 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Technical Service Bulletins > Page 10422 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Technical Service Bulletins > Page 10423 Truck Bed: Description and Operation PICKUP BED The pickup bed consists of the following components: - bed extender (optional) - box inner panel - body side outer moulding - body side outer panels - cargo divider (optional) - front body extension panels - fuel filler door - fuel filler housing - pickup bed inner tie-downs - pickup bed exterior tie-downs - pickup bed reinforcement assembly - power point receptacle - power point receptacle panel - rear wheel house panels - tonneau cover (optional) - tailgate assembly - wiring harnesses Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Adjustments > Pickup Bed Alignment Truck Bed: Adjustments Pickup Bed Alignment PICKUP BED ALIGNMENT 1. Remove the four bumper cover screws. 2. Loosen the pickup bed bolts. 3. Center the pickup bed to the rear of the cab. 4. Align the leading edge of the pickup bed and the rear of the cab to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Adjustments > Pickup Bed Alignment > Page 10426 5. Tighten the pickup bed bolts. 6. Install the four bumper cover screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Adjustments > Pickup Bed Alignment > Page 10427 Truck Bed: Adjustments Pickup Bed Lean - Measurements PICKUP BED LEAN - MEASUREMENTS 1. Check the vehicle ride height. 2. Check the vehicle frame height. 3. Measure and record the distance from the top center of both wheel well lips and calculate the difference. 4. If the difference between the two sides is between 0 and 6.50 mm (0 and 0.25 in) do nothing. 5. If the difference between the two measurements is 6.50 and 18.00 mm (0.25 and 0.70 in) shim the axle. 6. If the difference between the two measurements is between 18.00 and 30.50mm (0.70 and 1.20 in) shim the pickup bed. 7. If the difference is greater than 30.50 mm (1.20 in) shim both the axle and the pickup bed. 8. Align the pickup bed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Adjustments > Pickup Bed Alignment > Page 10428 Truck Bed: Adjustments Pickup Bed Shimming PICKUP BED SHIMMING 1. Determine the need for shimming. 2. Loosen the pickup bed bolts. 3. NOTE: Label the pickup bed bolts because they are not identical and must be installed in the same location that they are removed from. Remove the bolts on the low side of the pickup bed. 4. Raise the low side of the pickup bed and install shims between the top of the frame and the bottom of the pickup bed crossmembers. 5. Install and tighten the pickup bed bolts. 6. Align the pickup bed. 7. Recheck the vehicle lean. 8. Align the rear bumper cover as necessary. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Adjustments > Pickup Bed Alignment > Page 10429 Truck Bed: Adjustments Axle Shimming AXLE SHIMMING NOTE: A side to side lean may "be adjusted by 6 mm (0.24 in) by placing a shim between the rear spring (5560) and the axle on the low side of the vehicle. 1. Determine the need for shimming. 2. Without removing the tires from the ground, raise the vehicle enough to take the weight off of the rear springs. 3. Loosen the rear axle U-bolt nuts. - Separate the spring and the axle approximately 13 mm (0.5 in). 4. NOTE: On 4x4 vehicles place the shim between the rear spring and the axle spacer. Install the shim. 5. Tighten the rear axle U-bolt nuts. 6. Lower the vehicle. 7. Recheck the vehicle lean. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Pickup Bed Truck Bed: Service and Repair Pickup Bed PICKUP BED Removal and Installation 1. Disconnect the battery ground cable. 2. If equipped, remove the tonneau cover. 3. If equipped, remove the cargo divider. 4. Remove the tailgate assembly. 5. Remove the fuel filler cap. 6. Remove the fuel tank filler pipe screws. 7. Remove the bumper cover screws. 8. NOTE: Label the pickup bed bolts because they are not identical and must be installed in the same location that they are removed. Remove the pickup bed bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Pickup Bed > Page 10432 9. CAUTION: Protect the paint on the pickup bed and cab as the pickup bed is lifted. Disconnect the pickup bed wiring harness electrical connectors. 1. Lift the rear of the pickup bed. 2. Position a suitable support between the pickup bed and the vehicle frame. 3. Disconnect the three electrical connectors. 10. With an assistant, remove the pickup bed and place it on a suitable support. 11. to install, reverse the removal procedures. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Pickup Bed > Page 10433 Truck Bed: Service and Repair Panel - Rear Wheel House PANEL - REAR WHEEL HOUSE Removal and Installation LH Side 1. Remove the fuel filler cap. 2. Remove the fuel tank filler pipe screws. All 3. Remove the bumper cover screws. 4. Remove the rear wheel housing panel. 1. Remove the four rear wheel house panel screws. 2. Remove the wheel house panel screws. 3. Remove the wheel house panel 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Pickup Bed > Page 10434 Truck Bed: Service and Repair Pickup Bed - Inner Box PICKUP BED - INNER BOX Removal and Installation 1. Remove the pickup bed reinforcement. 2. Remove the rear wheel house panel screws. 3. Remove the screws and the front body extension panels. 1 Remove the ten screws. 2 Remove the panels. 4. To install, reverse the removal procedure. - Transfer all components as necessary Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Pickup Bed > Page 10435 Truck Bed: Service and Repair Pickup Bed - Exterior Tie-Down PICKUP BED - EXTERIOR TIE-DOWN Removal 1. Remove the pickup bed exterior tie-down. 1. Remove the bolts. 2. Remove the pickup bed exterior tie-down. Installation 1. CAUTION: When installing the pickup bed exterior tie-down make sure to correctly align the locating tabs. Position the pickup bed exterior tie-down to the panel and install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10450 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10451 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10452 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10453 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10454 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10455 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10456 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10457 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10458 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10459 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10460 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10461 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10462 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10463 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10464 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10465 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10466 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10467 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10468 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10469 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10470 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10475 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10481 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10482 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10483 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10484 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10485 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10486 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10487 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10488 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10489 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10490 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10491 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10492 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10493 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10494 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10495 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10496 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10497 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10498 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10499 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10500 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10501 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10506 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 10507 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 10510 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 10511 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the speed control deactivator switch electrical connector. 3. Remove the speed control deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 10518 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect the electrical connector. 2. Depress the locking tab and rotate the speed control cable cap to remove. 3. Disconnect the speed control cable from the speed control servo pulley. 1 Gently push the retaining spring. 2 Disconnect the speed control cable slug. 4. Remove the bolt and the speed control servo and bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 10519 5. Remove the bolts and separate the bracket from the speed control servo. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the rubber seal is fully seated onto the speed control cable cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement Technical Service Bulletin # 03S03 Date: 030801 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10528 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10529 Attachment I - Administrative Information OASIS Use OASIS to determine if a vehicle is eligible for this recall. Note: Some of the vehicles affected by this program are also affected by program 03S04. Affected customers will receive one letter describing both programs. For customer convenience please perform both programs during one customer visit. PROMPTLY CORRECT Promptly correct all affected in-stock and sold vehicles on your FSA VIN Lists. Also correct other affected vehicles identified in OASIS which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any of your affected owners whose names are not on your VIN lists but identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. Note: Your FSA VIN list may contain customer names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow- up necessary to complete this action. Advise regional office if an owner cannot be contacted or does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121. Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10530 specified in the reimbursement plan. Refund Claiming Information Program Code: 03S03 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below. For the first 30 days after program launch emergency status orders can be placed by calling the Special Service Support Center at 1-800-325-5621. ^ For Stock Orders effective immediately follow normal order process. ^ For Interim Orders effective immediately follow normal order process. ^ For Emergency Orders within the first 30 days after launch call 1-800-325-5621. For Emergency Orders 31 days after launch follow normal order process. The DOR/COR for this program is 50308. This number identifies parts ordered for this recall through the Special Service Support Center (1-800-325-5621). USE OF "CHECKING GAUGE" A "Checking Gauge" is utilized in this recall during Step 6 of the Technical Instructions. Gauges will be shipped to the dealership (quantity of 4 gauges per dealer). It is expected that tools will arrive at the dealership the week of September 2, 2003. A limited number of additional gauges may be ordered at no-charge by calling the Special Service Support Center at 1-800-325-5621. Alternatively, dealers can use an accurate measuring device such as digital calipers. PARTS RETENTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10531 Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." DEALER PRICE For latest prices, refer to DOES II or updated price book. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information INSPECTION 1. Locate the speed control cable identification number. Read the second to last letter. See Figure 1. ^ If the letter is a "T", no service is required. Release the vehicle. If the letter is a "D", continue with this inspection. 2. Remove the snow/ice shield. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10532 3. Visually inspect the cable for any of the following unacceptable conditions (see Figure 3): ^ Cover flared or split. ^ Core wire exposed when no tension is applied to the cable. ^ Cable is kinked. Replace the cable if any of the above conditions are found. For replacement and adjustment procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual. If none of these conditions are found, continue with the next step of this procedure. 4. WARNING: BE SURE TO MARK THE STRAND COVER AT THE VERY POINT WHERE IT ENTERS THE NOTCHED CABLE HOUSING. FAILURE TO MARK THE COVER AND MEASURE THE DISTANCE ACCURATELY (AS OUTLINED IN STEP 6) MAY RESULT IN FAILURE TO REPLACE AN UNACCEPTABLE CABLE. NOTE: Use a suitable marker such as a fine point paint marker or a felt-tipped marking pen. Brush-on touchup paint may also be used. DO NOT use a blunt marker or one that has a worn-out tip. It could cause your measurement to be incorrect. Whichever marking device you decide to use, it must leave a clean, straight line at the very point where the strand cover enters the notched cable housing. You will be measuring, in very small increments, the distance from the very edge of the mark you make to a certain point on the cable assembly. THE MEASUREMENT MUST NOT INCLUDE THE THICKNESS OF THE MARK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10533 Clean the cable if necessary, then using a suitable marking device, mark the strand cover at the point where the cover enters the notched cable housing. See Figure 4. 5. Disconnect the speed control cable connector from the throttle body cam by pulling the connector upward. See Figure 4. 6. CAUTION: When performing the following check, you will be instructed to pull the connector taut. Use only your hand to pull the connector. DO NOT use any type of tool to do this or damage to the cable may occur. CAUTION: Do not grasp the cable so tightly that you will kink the cable. NOTE: When pulling the connector, the strand cover may or may not be pulled out of the notched cable housing. For the purpose of this inspection, either is acceptable. NOTE: The following check can be made using either the 4 mm checking gauge supplied to each dealership or a Vernier caliper (analog dial or electronic LCD display). Pull the connector taut (toward the front of the vehicle). See Figure 5. A) If the strand cover does not pull out of the notched cable housing, no further service is required. Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10534 B) If the strand cover is pulled out of the notched cable housing, using either the supplied 4 mm checking gauge or a Vernier caliper, measure the distance from the inside edge of the mark to the end of the exposed strand cover. Do not include the thickness of the mark when taking the measurement. See Figures 5 and 6. ^ If the measurement is 4 mm (5/32-inch or 0.157-inch) or greater, no further service is required. Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle. ^ If the measurement is less than 4 mm (5/32-inch or 0.157-inch), the speed control cable must be replaced. For replacement and adjustment procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10535 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10536 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement Technical Service Bulletin # 03S03 Date: 030801 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10542 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10543 Attachment I - Administrative Information OASIS Use OASIS to determine if a vehicle is eligible for this recall. Note: Some of the vehicles affected by this program are also affected by program 03S04. Affected customers will receive one letter describing both programs. For customer convenience please perform both programs during one customer visit. PROMPTLY CORRECT Promptly correct all affected in-stock and sold vehicles on your FSA VIN Lists. Also correct other affected vehicles identified in OASIS which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any of your affected owners whose names are not on your VIN lists but identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. Note: Your FSA VIN list may contain customer names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow- up necessary to complete this action. Advise regional office if an owner cannot be contacted or does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121. Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10544 specified in the reimbursement plan. Refund Claiming Information Program Code: 03S03 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below. For the first 30 days after program launch emergency status orders can be placed by calling the Special Service Support Center at 1-800-325-5621. ^ For Stock Orders effective immediately follow normal order process. ^ For Interim Orders effective immediately follow normal order process. ^ For Emergency Orders within the first 30 days after launch call 1-800-325-5621. For Emergency Orders 31 days after launch follow normal order process. The DOR/COR for this program is 50308. This number identifies parts ordered for this recall through the Special Service Support Center (1-800-325-5621). USE OF "CHECKING GAUGE" A "Checking Gauge" is utilized in this recall during Step 6 of the Technical Instructions. Gauges will be shipped to the dealership (quantity of 4 gauges per dealer). It is expected that tools will arrive at the dealership the week of September 2, 2003. A limited number of additional gauges may be ordered at no-charge by calling the Special Service Support Center at 1-800-325-5621. Alternatively, dealers can use an accurate measuring device such as digital calipers. PARTS RETENTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10545 Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." DEALER PRICE For latest prices, refer to DOES II or updated price book. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information INSPECTION 1. Locate the speed control cable identification number. Read the second to last letter. See Figure 1. ^ If the letter is a "T", no service is required. Release the vehicle. If the letter is a "D", continue with this inspection. 2. Remove the snow/ice shield. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10546 3. Visually inspect the cable for any of the following unacceptable conditions (see Figure 3): ^ Cover flared or split. ^ Core wire exposed when no tension is applied to the cable. ^ Cable is kinked. Replace the cable if any of the above conditions are found. For replacement and adjustment procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual. If none of these conditions are found, continue with the next step of this procedure. 4. WARNING: BE SURE TO MARK THE STRAND COVER AT THE VERY POINT WHERE IT ENTERS THE NOTCHED CABLE HOUSING. FAILURE TO MARK THE COVER AND MEASURE THE DISTANCE ACCURATELY (AS OUTLINED IN STEP 6) MAY RESULT IN FAILURE TO REPLACE AN UNACCEPTABLE CABLE. NOTE: Use a suitable marker such as a fine point paint marker or a felt-tipped marking pen. Brush-on touchup paint may also be used. DO NOT use a blunt marker or one that has a worn-out tip. It could cause your measurement to be incorrect. Whichever marking device you decide to use, it must leave a clean, straight line at the very point where the strand cover enters the notched cable housing. You will be measuring, in very small increments, the distance from the very edge of the mark you make to a certain point on the cable assembly. THE MEASUREMENT MUST NOT INCLUDE THE THICKNESS OF THE MARK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10547 Clean the cable if necessary, then using a suitable marking device, mark the strand cover at the point where the cover enters the notched cable housing. See Figure 4. 5. Disconnect the speed control cable connector from the throttle body cam by pulling the connector upward. See Figure 4. 6. CAUTION: When performing the following check, you will be instructed to pull the connector taut. Use only your hand to pull the connector. DO NOT use any type of tool to do this or damage to the cable may occur. CAUTION: Do not grasp the cable so tightly that you will kink the cable. NOTE: When pulling the connector, the strand cover may or may not be pulled out of the notched cable housing. For the purpose of this inspection, either is acceptable. NOTE: The following check can be made using either the 4 mm checking gauge supplied to each dealership or a Vernier caliper (analog dial or electronic LCD display). Pull the connector taut (toward the front of the vehicle). See Figure 5. A) If the strand cover does not pull out of the notched cable housing, no further service is required. Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10548 B) If the strand cover is pulled out of the notched cable housing, using either the supplied 4 mm checking gauge or a Vernier caliper, measure the distance from the inside edge of the mark to the end of the exposed strand cover. Do not include the thickness of the mark when taking the measurement. See Figures 5 and 6. ^ If the measurement is 4 mm (5/32-inch or 0.157-inch) or greater, no further service is required. Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle. ^ If the measurement is less than 4 mm (5/32-inch or 0.157-inch), the speed control cable must be replaced. For replacement and adjustment procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10549 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 10550 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Page 10551 Cruise Control Servo Cable: Adjustments 1. Remove the speed control actuator cable clip. 2. Adjust the speed control actuator cable. 1 Hold the throttle body cam in the closed position. 2 Pull on the speed control actuator cable housing to remove any slack. 3 Back off the speed control actuator cable one notch and install the clip. NOTE: ^ The speed control actuator cable must not be pulled tight for correct operation. ^ The throttle body cam will automatically spring set to the closed position. The throttle body cam must be in the closed position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Page 10552 Cruise Control Servo Cable: Service and Repair REMOVAL Early production vehicles 1. Remove the accelerator cable snow shield. 1 Detach the cable. 2 Remove the bolts. 3 Remove the accelerator cable snow shield. 2. Separate the speed control cable from the intake manifold. 1 Remove the bolt. 2 Disconnect the cable from the throttle linkage. Late production vehicles 3. Remove the bolts and the accelerator cable snow shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Page 10553 4. Separate the speed control cable from the intake manifold. 1 Disconnect the cable from the throttle linkage. 2 Depress the locking tabs and separate the speed control cable from the intake manifold. All vehicles 5. Depress the locking tab and rotate the speed control cable cap to remove. 6. Disconnect the speed control cable from the speed control servo pulley and remove the speed control cable. 1 Gently push the retaining spring. 2 Disconnect the speed control cable slug from the speed control servo pulley. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Page 10554 ^ On early production vehicles, adjust the speed control cable. NOTE: Make sure the rubber seal is fully seated onto the speed control cable cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the screws and the steering wheel rear cover. 3. Remove the ribbon harness from the clips. 4. Disconnect the horn contact electrical connectors. 5. Remove the screws and the right side horn contact. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 10558 6. Remove the screws and the speed control switch assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10568 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10569 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10570 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10571 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10572 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10573 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10574 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10575 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10576 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10577 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10578 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10579 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10580 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10581 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10582 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10583 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10584 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10585 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10586 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10587 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10588 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10593 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10599 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10600 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10601 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10602 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10603 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10604 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10605 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10606 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10607 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10608 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10609 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10610 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10611 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10612 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10613 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10614 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10615 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10616 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10617 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10618 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10619 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10624 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 10625 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 10628 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 10629 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the speed control deactivator switch electrical connector. 3. Remove the speed control deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the screws and the steering wheel rear cover. 3. Remove the ribbon harness from the clips. 4. Disconnect the horn contact electrical connectors. 5. Remove the screws and the right side horn contact. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 10636 6. Remove the screws and the speed control switch assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 10646 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 10652 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10658 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10659 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10665 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10666 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Page 10667 Audible Warning Device: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10673 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10674 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10675 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10676 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10677 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10678 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10679 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10680 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10681 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10682 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10683 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10684 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10685 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10686 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10687 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10688 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10689 Audible Warning Device Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10690 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10691 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10692 Audible Warning Device Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10693 Audible Warning Device Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 10694 Audible Warning Device Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10699 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10700 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10701 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10702 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10703 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10704 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10705 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10706 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10707 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10708 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10714 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10715 Cigarette Lighter: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10716 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10717 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10718 Cigarette Lighter: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10719 Diagram 501-12-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions Compass: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10724 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10725 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10726 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10727 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10728 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10729 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10730 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10731 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10732 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10733 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10734 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10735 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10736 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10737 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10738 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10739 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10740 Compass: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10741 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10742 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10743 Compass: Electrical Diagrams Diagram 419-11-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 10744 Diagram 419-11-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 10745 Compass: Service Precautions CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 10746 Compass: Description and Operation A compass and outside temperature display are contained in the overhead console. The compass and temperature display can be turned off and on by pressing the MODE switch in the overhead console. The vehicle heading is displayed as one of N, NE, E, SE, S, SW, W, and NW. Compass Accuracy Magnetic mounted devices like antennas and luggage racks should not be located on the front third of the vehicle roof. Placing these devices near the compass will cause inaccurate directional readings. If these devices must be used, accuracy may be improved by recalibrating the compass while the devices are installed on the vehicle. Driving near power lines, or driving in the area of large iron or steel structures can temporarily change the compass heading. If the compass remains inaccurate after driving near such objects, demagnetize the vehicle and recalibrate the compass. Most geographic areas (zones) have a magnetic north compass point that varies slightly from the northerly direction on maps. This variation is four degrees between the adjacent zones and will become noticeable as the vehicle crosses multiple zones. A correct zone setting eliminates the error. Refer to Compass Zone Adjustment. Temperature, Outside Air The thermometer sensor is attached to the radiator frame behind the grille. The temperature can be displayed in Celsius or Fahrenheit by pressing the MODE switch. If the outside temperature falls below 3.3°C (38°F), the display will alternate from ICE to the outside temperature at a two-second rate for one minute. The outside air temperature reading can be affected by engine heat when the vehicle is idling or has been off for less than two hours. The compass and thermometer will limit the increase of the displayed temperature to one degree per minute at very low speeds or immediately after the ignition is turned on. After two minutes at a sustained speed of at least 53 km/h (33 mph), effects of engine heat are minimal and the compass will display the current outside temperature reading. Temperature decreases are always updated immediately. If the outside air temperature sensor is short circuited or open, the display will show 60°C (140°F) or -40°C (-40°F) respectively in place of temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compass: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the electronic compass. 2. Visually inspect for obvious signs of mechanical and electrical damage. Visual Inspection Chart 3. If inspection reveals an obvious concern(s) that can be readily identified, repair or install a new component as necessary. 4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10749 Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10750 Compass: Pinpoint Tests Connector Circuit Reference Refer to Vehicle/Diagrams for schematic and connector information. Pinpoint Test Notes NOTE: - Always set the zone, calibrate, and demagnetize a vehicle before installing a new electronic compass module. - After installing a new electronic compass module, always set the zone and calibrate. Test A: Compass Is Inaccurate/Inoperative A1 - A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10751 A3 - A4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10752 A5 - A6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10753 A7 - A8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10754 A9 - A10 Test B: Outside Air Temperature Is Inaccurate/Inoperative Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10755 B1 - B3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10756 B3 - B5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10757 B5 - B6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10758 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment Compass: Adjustments Compass Zone Adjustment 1. Determine the zone in which the vehicle is located. 2. Press and hold the MODE button until VAR appears on the display. Release the MODE button. 3. Momentarily press the MODE button to increment the zone by one. Set the zone according to the map. NOTE: After a few seconds, the compass will exit the VAR mode if the button is no longer pressed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 10761 Compass: Adjustments Calibration Adjustment 1. Start the vehicle. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all doors are closed. 2. Locate the electronic compass/temperature display on the overhead console, press and hold the MODE button until CAL appears in the display, then release the MODE button. NOTE: To exit CAL mode before carrying out a compass adjustment, turn the ignition switch to the OFF position. 3. Drive the vehicle slowly (less than 5 km/h [3 mph]) in complete circles until CAL disappears from the display. NOTE: If the CAL indicator does not turn off after the vehicle has been driven in a circle no more than five times, demagnetize the vehicle and repeat the procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 10762 Compass: Adjustments Vehicle Demagnetizing CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: - The demagnetizing process requires the use of a demagnetizing coil commonly used by television repair technicians to demagnetize television tubes. - To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. - During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the entire surface of the vehicle roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. Carry out the Compass Zone Adjustment procedure. 3. Carry out the Compass Calibration Adjustment procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Electronic With Moonroof Compass: Service and Repair Electronic With Moonroof REMOVAL 1. Remove the overhead console. 2. Remove the screws. 3. Disconnect the harness connector and remove the switches and the harness from the compass module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Electronic With Moonroof > Page 10765 Compass: Service and Repair Electronic With Storage Console REMOVAL 1. Remove the overhead console. 2. Remove the screws. 3. Push the latch and remove the compass/lamp bezel from the console housing. 4. Disconnect the harness connector and remove the switches and the harness from the compass module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Page 10766 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor connector. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side floor connector. 11. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10772 STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector beneath the front seat. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag electrical connector beneath the front seat. 11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat. 12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side air bag electrical connector beneath the front seat. 13. Reconnect the battery ground cable. Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10773 NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10774 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10775 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10776 Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10777 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10778 Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10779 14. Install the two screws. 15. Close the glove compartment door. 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10780 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Procedures For Repair Operations Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10781 accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10782 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10783 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10784 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10785 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic tool from the driver seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10786 8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. Prove out the system. Seats Not Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the front passenger seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the driver seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver seat. 10. Reconnect the battery ground cable. 11. Prove out the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10787 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10788 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Testing and Inspection Dimmer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Testing and Inspection > Page 10792 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pin 6 using a fused (10A) jumper to 12V DC power and pin 9 to ground. Measure the voltage between pin 8 and pin 9 while rotating the thumbwell from full illumination to no illumination. If the voltage smoothly decreases from near 12 volts to near 0 volts, the illumination dimmer is okay. If not, replace the main light switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Driver Side Door Switch: Diagrams Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Driver Side > Page 10797 Door Switch: Diagrams Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 10800 Door Switch: Service and Repair Door Ajar Switch-Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection Fuel Gauge: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Page 10804 Fuel Gauge: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 4. Disconnect the driver air bag electrical connector. 5. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 8. If equipped with side air bags, remove the front seats. 9. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag floor connector. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side floor connector. 11. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing side air bag concerns, and also when repairing any in-seat component in vehicles equipped with side air bags. ^ The other procedure does not require front seat removal. This procedure will be used when diagnosing a concern not related to the Supplemental Restraint System (SRS). 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10810 STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated using the appropriate deactivation procedure. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system, the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag electrical connector to the clockspring behind the lower steering column opening finish panel. 5. Disconnect the driver air bag electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the vehicle harness side of the clockspring connector. 7. Disconnect the passenger air bag. 8. Attach a restraint system diagnostic tool 418-F088 (105-R0012) to the harness side of the passenger air bag connector. 9. If equipped with side air bags, disconnect the passenger side air bag connector beneath the front seat. 10. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the passenger side air bag electrical connector beneath the front seat. 11. If equipped with side air bags, disconnect the side air bag connector beneath the driver seat. 12. If equipped with side air bags, attach a restraint system diagnostic tool 418-133 (40-009) to the driver side air bag electrical connector beneath the front seat. 13. Reconnect the battery ground cable. Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10811 NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10812 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10813 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10814 Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10815 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10816 Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10817 14. Install the two screws. 15. Close the glove compartment door. 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10818 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Procedures For Repair Operations Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10819 accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. 7. Remove the two steering wheel back cover plugs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10820 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10821 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10822 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10823 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. If equipped with side air bags, remove the restraint system diagnostic tool from the driver seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the passenger seat floor connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, install the front seats. 6. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10824 8. Reconnect the passenger air bag electrical connector. 9. Reconnect the battery ground cable. 10. Prove out the system. Seats Not Removed 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the passenger air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Reconnect the passenger air bag electrical connector. 6. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the front passenger seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. If equipped with side air bags, reconnect the side air bag electrical connector beneath the passenger seat. 8. If equipped with side air bags, remove the restraint system diagnostic tool from the floor connector beneath the driver seat. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. If equipped with side air bags, reconnect the side air bag electrical connector beneath the driver seat. 10. Reconnect the battery ground cable. 11. Prove out the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10825 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10826 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair REMOVAL WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF INCORRECTLY HANDLED. WEAR EYE PROTECTION WHEN INSTALLING NEW ILLUMINATION BULBS. 1. Remove the instrument cluster. 2. Remove the illumination sockets and bulbs. 3. Remove the indicator sockets and bulbs. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Service and Repair Instrument Panel Circuit Board: Service and Repair REMOVAL WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF INCORRECTLY HANDLED. WEAR EYE PROTECTION WHEN INSTALLING NEW BULBS. CAUTION: If gauges are being removed from the cluster assembly, do not remove the gauge pointers. Magnetic gauges cannot be recalibrated. 1. Remove the instrument cluster; refer to Instrument Panel. 2. Remove the illumination and indicator bulbs; refer to Warning Indicator Bulb. 3. Remove the gauges; refer to Gauges. 4. Remove the 19 instrument gauge clips. NOTE: New gauge clips must be used for assembly. 5. Remove the instrument cluster printed circuit. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10841 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10842 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10843 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10849 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10850 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10851 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 10855 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions Lamp Out Indicator: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10860 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10861 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10862 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10863 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10864 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10865 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10866 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10867 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10868 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10869 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10870 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10871 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10872 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10873 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10874 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10875 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10876 Lamp Out Indicator: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10877 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10878 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10879 Lamp Out Indicator: Electrical Diagrams Diagram 413-09-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10880 Diagram 413-09-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10881 Diagram 413-09-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10882 Diagram 413-09-00-4 Diagram 413-09-00-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10883 Diagram 413-09-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10884 Diagram 413-09-00-7 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10885 Diagram 413-09-00-8 Diagram 413-09-00-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10886 Diagram 413-09-00-10 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection Odometer: Testing and Inspection To test the odometer accuracy, drive the vehicle over a measured distance of at least 16 consecutive kilometers (10 miles). Check measured distance against odometer measured distance. Acceptable odometer measured distance is 15.5-16.7 km (9.6-10.4 miles). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > Page 10893 Odometer: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > Resetting Oil Change Reminder Lamp Oil Change Reminder Lamp: Service and Repair Resetting Oil Change Reminder Lamp Oil Change Reset Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of 12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL CHANGE RESET control for five seconds. The message center will count down for five seconds. After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have established a personalized oil reset percentage, the display will show that percentage instead of 100%.) This reset procedure should be performed only after an oil change to ensure accurate oil life indications. Your personalized oil reset percentage allows you to establish a smaller oil change interval than the manufacturer's recommended interval. To establish your personalized oil reset percentage: 1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display is still counting gown the five seconds to reset. The display will change to START OIL LIFE AT XXX%. 2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil reset percentage you desire. Your choices are 100%, 90%, 80%, 70%, 60%, 50% 40% and 30%. 3. Press the RESET control to complete the procedure. Pressing any control other than RESET of OIL CHANGE RESET will abort this procedure and will not establish your new personalized oil reset percentage. When your personalized oil reset percentage has been established, it will be used beginning with the completion of your next OIL CHANGE RESET procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > Resetting Oil Change Reminder Lamp > Page 10898 Oil Change Reminder Lamp: Service and Repair No Reset Oil Life Mode The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the L (low) mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection > Page 10902 Oil Pressure Gauge: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10915 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10916 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10917 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10918 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10919 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10920 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10921 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10922 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10923 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10924 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10925 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10926 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10927 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10928 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10929 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10930 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10931 Audible Warning Device Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10932 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10933 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10934 Audible Warning Device Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10935 Audible Warning Device Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 10936 Audible Warning Device Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10945 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10946 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10947 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10953 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10954 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10955 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 10959 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Application and ID Seat Belt Reminder Lamp: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection Dimmer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection > Page 10967 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pin 6 using a fused (10A) jumper to 12V DC power and pin 9 to ground. Measure the voltage between pin 8 and pin 9 while rotating the thumbwell from full illumination to no illumination. If the voltage smoothly decreases from near 12 volts to near 0 volts, the illumination dimmer is okay. If not, replace the main light switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Driver Side Door Switch: Diagrams Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Driver Side > Page 10972 Door Switch: Diagrams Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 10975 Door Switch: Service and Repair Door Ajar Switch-Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection Speedometer Head: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > Page 10982 Speedometer Head: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection Tachometer: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection > Page 10986 Tachometer: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection 1. Disconnect water temperature indicator sender unit C1061. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C1061, circuit 39 (RD/WH), harness side and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid-range. Key OFF. 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. Return to the Pinpoint Test. See: Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Page 10990 Temperature Gauge: Service and Repair For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 10994 Temperature Sensor (Gauge): Service and Repair Sender Unit-Water Temperature Indicator Removal and Installation 1. Partially drain the cooling system. 2. Remove the thermostat. 3. Disconnect the electrical connector. 4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor > Page 11005 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11014 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11020 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11023 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11024 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11025 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11026 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11027 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11028 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11029 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11030 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11031 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11032 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11033 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11034 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11035 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11036 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11037 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11038 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11039 Brake Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11040 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11041 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11042 Brake Lamp: Electrical Diagrams DETAILED DIAGRAMS Diagram 417-01-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11043 Diagram 417-01-00-11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11044 Diagram 417-01-00-12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11045 Diagram 417-01-00-13 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11046 Diagram 417-01-00-14 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11047 Diagram 417-01-00-15 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11048 Diagram 417-01-00-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11049 Diagram 417-01-00-17 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11050 Diagram 417-01-00-18 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11051 Diagram 417-01-00-19 Diagram 417-01-00-20 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11052 Diagram 417-01-00-22 RELATED DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11053 Diagram 413-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11054 Diagram 417-04-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. Visual Inspection Chart 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11057 Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11058 Brake Lamp: Pinpoint Tests G1 - G2 Test H: One Or More Stoplamps Are Inoperative Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11059 H1 - H2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11060 H2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11061 H3 - H4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11062 H4 - H5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11063 H6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11064 H7 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 11065 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 11069 Brake Pedal Position Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 11070 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11082 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 11088 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Center Mounted Brake Lamp: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11091 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11092 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11093 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11094 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11095 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11096 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11097 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11098 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11099 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11100 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11101 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11102 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11103 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11104 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11105 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11106 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11107 Center Mounted Brake Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11108 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11110 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11111 Center Mounted Brake Lamp: Electrical Diagrams DETAILED DIAGRAMS Diagram 417-01-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11112 Diagram 417-01-00-11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11113 Diagram 417-01-00-12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11114 Diagram 417-01-00-13 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11115 Diagram 417-01-00-14 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11116 Diagram 417-01-00-15 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11117 Diagram 417-01-00-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11118 Diagram 417-01-00-17 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11119 Diagram 417-01-00-18 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11120 Diagram 417-01-00-19 Diagram 417-01-00-20 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11121 Diagram 417-01-00-22 RELATED DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11122 Diagram 413-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11123 Diagram 417-04-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Diagrams > Page 11131 Courtesy Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Diagrams > Page 11132 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 11137 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 11138 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Testing and Inspection Dimmer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Testing and Inspection > Page 11142 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pin 6 using a fused (10A) jumper to 12V DC power and pin 9 to ground. Measure the voltage between pin 8 and pin 9 while rotating the thumbwell from full illumination to no illumination. If the voltage smoothly decreases from near 12 volts to near 0 volts, the illumination dimmer is okay. If not, replace the main light switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11146 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11147 Battery Discharge Protection Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11148 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11153 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11154 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11155 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11156 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11157 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11158 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11159 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11160 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11161 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11162 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11163 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11164 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11165 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11166 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11167 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11168 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11169 Dome Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11170 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11171 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11172 Dome Lamp: Electrical Diagrams Diagram 417-02-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11173 Diagram 417-02-00-3 Diagram 417-02-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 11174 Dome Lamp: Service and Repair REMOVAL 1. Disconnect the battery. 2. Remove the lamp lens. 1 Use a thin-bladed tool to carefully pry the dome lamp lens out. ^ Install a new bulb if necessary. 3. Remove the lamp. 1 Remove the screws. 2 Lower the lamp, disconnect the electrical connector and remove the lamp from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Driver Side Door Switch: Diagrams Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Driver Side > Page 11179 Door Switch: Diagrams Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 11182 Door Switch: Service and Repair Door Ajar Switch-Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay > Page 11189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 11190 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 11191 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 11195 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 11200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 11201 Hazard Flasher Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 11202 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 11206 Hazard Warning Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 11207 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information Headlamp Bulb: Technician Safety Information WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 11213 Headlamp Bulb: Vehicle Damage Warnings CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn the headlamps on with the bulb removed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 11214 Headlamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn the headlamps on with the bulb removed. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb retainer counterclockwise and remove. 3. Remove the headlamp bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 11218 Headlamp Dimmer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 11219 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11223 Headlamp Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11224 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11225 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel center finish panel. 1 Remove the screws. 2 Remove the instrument panel center finish panel. ^ Disconnect electrical connectors. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11226 5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the column gear shift lever out of the way. 7. Position the cluster finish panel aside. 1 Remove the screws. 2 Position the cluster finish panel aside. 8. Remove the cluster finish panel. 1 Disconnect the electrical connectors and remove the headlamp switch knob. 2 Remove the cluster finish panel. 9. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11227 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11232 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11233 Horn Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11234 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag. 2. Remove the switch. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the screws and the switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations Interior Lighting Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11243 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11244 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11245 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11246 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11247 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11248 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11249 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11250 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11251 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11252 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11253 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11254 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11255 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11256 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11257 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11258 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11259 Interior Lighting Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11260 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11261 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11262 Interior Lighting Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11263 Interior Lighting Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 11264 Interior Lighting Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11268 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11269 Interior Lighting Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11270 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions Lamp Out Indicator: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11275 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11276 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11277 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11278 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11279 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11280 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11281 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11282 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11283 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11284 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11285 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11286 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11287 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11288 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11289 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11290 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11291 Lamp Out Indicator: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11292 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11293 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11294 Lamp Out Indicator: Electrical Diagrams Diagram 413-09-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11295 Diagram 413-09-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11296 Diagram 413-09-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11297 Diagram 413-09-00-4 Diagram 413-09-00-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11298 Diagram 413-09-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11299 Diagram 413-09-00-7 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11300 Diagram 413-09-00-8 Diagram 413-09-00-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 11301 Diagram 413-09-00-10 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11306 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11307 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11308 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11309 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11310 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11311 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11312 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11313 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11314 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11315 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11316 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11317 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11318 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11319 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11320 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11321 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11322 License Plate Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11323 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11324 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11325 License Plate Lamp: Connector Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11326 License Plate Lamp: Electrical Diagrams DETAILED DIAGRAMS Diagram 417-01-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11327 Diagram 417-01-00-11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11328 Diagram 417-01-00-12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11329 Diagram 417-01-00-13 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11330 Diagram 417-01-00-14 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11331 Diagram 417-01-00-15 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11332 Diagram 417-01-00-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11333 Diagram 417-01-00-17 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11334 Diagram 417-01-00-18 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11335 Diagram 417-01-00-19 Diagram 417-01-00-20 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11336 Diagram 417-01-00-22 RELATED DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11337 Diagram 413-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11338 Diagram 417-04-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 11339 License Plate Lamp: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Parking Lamp; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions Map Light: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11344 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11345 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11346 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11347 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11348 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11349 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11350 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11351 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11352 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11353 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11354 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11355 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11356 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11357 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11358 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11359 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11360 Map Light: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11361 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11362 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11363 Map Light: Electrical Diagrams Diagram 417-02-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 11364 Diagram 417-02-00-3 Diagram 417-02-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Page 11365 Map Light: Service and Repair REMOVAL 1. Disconnect the battery. 2. Remove the lamp lens. 1 Use a thin-bladed tool to carefully pry the dome lamp lens out. ^ Install a new bulb if necessary. 3. Remove the lamp. 1 Remove the screws. 2 Lower the lamp, disconnect the electrical connector and remove the lamp from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 11370 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 11371 Parking Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 11372 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11377 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11378 Battery Discharge Protection Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11379 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Diagrams > Page 11383 Courtesy Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Diagrams > Page 11384 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 11388 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 11389 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay > Page 11395 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 11396 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 11397 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 11401 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 11402 Hazard Flasher Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 11403 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 11407 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 11408 Horn Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 11409 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Interior Lighting Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11415 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11416 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11417 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11418 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11419 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11420 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11421 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11422 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11423 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11424 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11425 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11426 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11427 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11428 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11429 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11430 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11431 Interior Lighting Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11432 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11433 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11434 Interior Lighting Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11435 Interior Lighting Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 11436 Interior Lighting Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11440 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11441 Interior Lighting Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11442 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 11446 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 11447 Parking Lamp Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 11448 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Page 11452 Trailer Lighting Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Page 11453 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Page 11457 Turn Signal Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Page 11458 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor > Page 11465 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 11469 Brake Pedal Position Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 11470 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Driver Side Door Switch: Diagrams Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Driver Side > Page 11475 Door Switch: Diagrams Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 11478 Door Switch: Service and Repair Door Ajar Switch-Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 11482 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 11486 Hazard Warning Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 11487 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 11491 Headlamp Dimmer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 11492 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11496 Headlamp Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11497 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11498 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel center finish panel. 1 Remove the screws. 2 Remove the instrument panel center finish panel. ^ Disconnect electrical connectors. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11499 5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the column gear shift lever out of the way. 7. Position the cluster finish panel aside. 1 Remove the screws. 2 Position the cluster finish panel aside. 8. Remove the cluster finish panel. 1 Disconnect the electrical connectors and remove the headlamp switch knob. 2 Remove the cluster finish panel. 9. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11500 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag. 2. Remove the switch. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the screws and the switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 11507 Turn Signal Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 11508 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 11509 Turn Signal Switch: Service and Repair Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 11510 5. Remove the multifunction switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multifunction switch. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 11515 OASIS CODES: 201000, 201200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11520 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11521 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11522 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11523 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11524 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11525 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11526 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11527 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11528 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11529 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11530 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11531 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11532 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11533 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11534 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11535 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11536 Tail Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11537 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11538 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11539 Tail Lamp: Electrical Diagrams DETAILED DIAGRAMS Diagram 417-01-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11540 Diagram 417-01-00-11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11541 Diagram 417-01-00-12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11542 Diagram 417-01-00-13 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11543 Diagram 417-01-00-14 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11544 Diagram 417-01-00-15 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11545 Diagram 417-01-00-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11546 Diagram 417-01-00-17 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11547 Diagram 417-01-00-18 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11548 Diagram 417-01-00-19 Diagram 417-01-00-20 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11549 Diagram 417-01-00-22 RELATED DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11550 Diagram 413-00-00-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11551 Diagram 417-04-00-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11552 Tail Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Parking Lamp; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11553 Tail Lamp: Service and Repair REMOVAL 1. Lower the tailgate. 2. Remove the plugs. 3. Remove the rear lamp assembly. 1 Remove the bolts. 2 Pull the lamp assembly rearward. ^ Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer tow lamps. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 3 (7.5A) - 7 (7.5A) - 36 (15A) ^ Circuitry ^ Trailer tow relay ^ Bulb(s) 4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11558 Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11559 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to Vehicle/Diagrams for schematic and connector information. V1 W1 - W2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11560 W2 X1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11561 X1 Y1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11562 Z1 - Z2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11563 Z2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11564 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 11565 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Page 11569 Trailer Lighting Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Page 11570 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions Trunk Lamp: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11575 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11576 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11577 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11578 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11579 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11580 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11581 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11582 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11583 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11584 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11585 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11586 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11587 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11588 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11589 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11590 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11591 Trunk Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11592 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11593 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11594 Trunk Lamp: Electrical Diagrams Diagram 417-02-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11595 Diagram 417-02-00-3 Diagram 417-02-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Page 11600 Turn Signal Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Page 11601 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 11605 Turn Signal Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 11606 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 11607 Turn Signal Switch: Service and Repair Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 11608 5. Remove the multifunction switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multifunction switch. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 11614 OASIS CODES: 201000, 201200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11619 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11620 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11621 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11622 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11623 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11624 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11625 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11626 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11627 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11628 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11629 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11630 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11631 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11632 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11633 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11634 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11635 Vanity Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11636 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11637 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11638 Vanity Lamp: Electrical Diagrams Diagram 417-02-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11639 Diagram 417-02-00-3 Diagram 417-02-00-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11645 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11646 Heated Glass Element Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11647 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11655 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11656 Heated Glass Element Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11657 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations Power Window Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11663 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11664 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11665 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11666 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11667 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11668 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11669 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11670 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11671 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11672 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11673 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11674 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11675 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11676 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11677 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11678 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11679 Power Window Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11680 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11681 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11682 Power Window Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11683 Power Window Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 11684 Power Window Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Diagram 700-01-00-2 Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Window Safety Relay Power Window Relay: Diagrams Window Safety Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Window Safety Relay > Page 11690 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay Power Window Relay: Testing and Inspection Window Safety Relay Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 11693 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 11694 Power Window Relay: Testing and Inspection One-Touch Window Relay Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 11695 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 11704 Power Window Switch: Diagrams Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 11705 Power Window Switch: Diagrams Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 11706 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11709 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11710 Power Window Switch: Testing and Inspection Power window Switch Passenger Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11711 Left Rear Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11712 Right Rear Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11713 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 11714 Power Window Switch: Service and Repair REMOVAL NOTE: Driver window control switch shown, all others are similar. Front door 1. Disconnect the battery ground cable. All doors 2. Remove the window control switch panel. ^ Disconnect the electrical connectors. 3. Remove the window control switch. ^ Release the locking clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations Power Window Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11721 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11722 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11723 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11724 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11725 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11726 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11727 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11728 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11729 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11730 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11731 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11732 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11733 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11734 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11735 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11736 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11737 Power Window Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11738 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11739 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11740 Power Window Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11741 Power Window Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 11742 Power Window Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 11748 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 11749 Front Door Window Motor: Service Precautions CAUTION: Use care not to damage the drum housing when removing the rear window glass motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 11750 Front Door Window Motor: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 3. Remove the water shield. 4. Disconnect the front door window regulator motor electrical connector. 5. Drill a 13 mm (0.52 in) hole using the locator in the door sheet metal as a guide. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 11751 6. Remove the bolts and the front door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Left Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Left > Page 11756 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Left > Page 11757 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Page 11758 Rear Door Window Motor: Service Precautions CAUTION: Use care not to damage the drum housing when removing the rear window glass motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor Rear Door Window Motor: Service and Repair Rear Door Window Regulator Motor REMOVAL 1. Remove the rear door window regulator. 2. Remove the rear door window regulator motor. 1 Remove the bolts. 2 Remove the rear door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 11761 Rear Door Window Motor: Service and Repair Rear Window Glass Motor REMOVAL 1. Remove the C-pillar trim panel. 2. Position the rear of the carpet aside. 3. Remove the water shield from over the rear window glass motor and discard. 4. Remove the rear window motor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the rear window glass motor. CAUTION: Use care not to damage the drum housing when removing the rear window glass motor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The rear window motor must be initialized after a repair is carried out. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 11762 Rear Door Window Motor: Service and Repair Rear Window Motor Initialization 1. Start with the ignition key in the OFF position. 2. Turn the ignition key to the ON position. 3. Press the rear window glass control switch vent button six times. 4. Turn the ignition key to the OFF position. 5. Press the rear window glass control switch vent button six more times. 6. Turn the ignition key to the ON position. At this point the rear window glass will move up and down approximately 20 mm (0.8 in). This movement signifies that the rear window glass motor has entered into the initialization mode. 7. Hold the rear window glass control switch in the full up position until the rear window glass stops in the full up position. NOTE: The rear window glass control switch must be held in the up or down position until the window glass stops moving. Failure to hold the switch will end the initialization operation. Then initialization will have to be re-started. 8. Hold the rear window glass control switch in the full down position until the rear window glass stops in the full down position. NOTE: If a repair is to be carried out on the rear window glass release the rear window glass control switch when it reaches the desired position. This will end the initialization operation. 9. Hold the rear window glass control switch in the full, up position until the rear window glass stops in the full up position. At this time the window will move up and down approximately 20 mm (0.8 in) signifying the rear window glass motor is initialized. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Diagram 700-01-00-2 Diagram 700-01-00-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Window Safety Relay Power Window Relay: Diagrams Window Safety Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Window Safety Relay > Page 11768 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay Power Window Relay: Testing and Inspection Window Safety Relay Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 11771 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 11772 Power Window Relay: Testing and Inspection One-Touch Window Relay Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Window Safety Relay > Page 11773 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 11778 Power Window Switch: Diagrams Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 11779 Power Window Switch: Diagrams Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 11780 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11783 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11784 Power Window Switch: Testing and Inspection Power window Switch Passenger Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11785 Left Rear Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11786 Right Rear Door Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11787 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 11788 Power Window Switch: Service and Repair REMOVAL NOTE: Driver window control switch shown, all others are similar. Front door 1. Disconnect the battery ground cable. All doors 2. Remove the window control switch panel. ^ Disconnect the electrical connectors. 3. Remove the window control switch. ^ Release the locking clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service Precautions Window Frame: Service Precautions CAUTION: Use care not to damage the pin-type retainers retaining the upper corner of the door glass top run. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Window Frame: Service and Repair Front Door REMOVAL 1. Remove the front door trim panel. 2. Remove the interior glass weather strip. 3. Release the two pin-type retainers. CAUTION: Use care not to damage the pin-type retainers retaining the upper corner of the door glass top run. 4. Remove the front door glass top run bolts. 5. Remove the front door glass top run. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door > Page 11794 Window Frame: Service and Repair Rear Door REMOVAL 1. Remove the rear door window glass. 2. Remove the rear door glass top run bolt. 3. Remove the door glass top run. CAUTION: Use care not to damage the pin-type retainers retaining the upper forward comer of the door glass top run. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed Back Window Glass: Service and Repair Fixed REMOVAL 1. Remove the C-pillar trim panel. 2. Remove the 15 rear window glass nuts and remove the rear window glass. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear window glass. ^ Start at the bottom middle and work around the window opening. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed > Page 11800 Back Window Glass: Service and Repair Power REMOVAL 1. Remove the C-pillar trim panel. 2. Position the rear of the carpet aside. 3. Position the rear window glass regulator access panel aside. 1 Remove the screws. 2 Remove the nut. 3 Position the rear window glass regulator access panel aside. 4. Remove the rear window weatherstrip moulding. 5. Position the rear window glass to the center position using the following procedure. 1 Start with the ignition key in the OFF position. 2 Turn the ignition to the ON position. 3 Press the rear window glass control switch vent button six times. 4 Turn the ignition key to the OFF position. 5 Press the rear window glass control switch vent button six more times. 6 Turn the ignition to the ON position. At this point the rear window will move up and down approximately 20 mm (0.8 in). This movement signifies that the rear window glass motor has entered into the initialization mode. 7 Hold the rear window glass control switch in the full up position until the rear window glass stops in the full up position. 8 Hold the rear window glass control switch in the full down position until the rear window glass stops in the full down position. 9 Hold the rear window glass control switch in the full up position until the rear window glass in the center position and release the switch. 10 Turn the key to the OFF position. 6. Remove the rear window glass bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed > Page 11801 7. Secure the rear window glass in the full up position. NOTE: When securing the rear window glass note that the rear window glass and module will be removed with the rear window glass in the secured position. 8. Remove the 12 rear window glass module nuts. 9. Push the rear window glass module out at the top. 10. Lift the rear window glass module from the rear of the cab to disengage the locating clip. NOTE: In order for the rear widow glass to function correctly the locating clip must engage the pinch weld at the rear of the cab during installation. 11. Remove the excess foam butyl from the window opening. 12. If necessary, remove the center rear window glass from the module. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed > Page 11802 1. To install, reverse the removal procedure. ^ Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear window glass module. ^ Start at the bottom and work around the module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Remove the front door belt line moulding. 1 Remove the nut. 2 Remove the moulding. CAUTION: Do not strike or force the front door belt line moulding during installation. The front door belt line moulding is made of aluminum and will be damaged. NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge of the sheet metal and the door panel shelf. 3. Remove the interior glass weatherstrip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 11806 4. Remove the front door window glass rivets. NOTE: Lower the window glass to access the rivets. 5. Remove the front door window glass through the outboard side of the front door. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Open the liftgate glass. 2. Remove the two heated rear window electrical connector covers. 3. Disconnect the two heated rear window electrical connectors. 4. Remove the two liftgate lifting cylinder pins. NOTE: An assistant may be needed to carry out this step. 5. Remove the liftgate window glass. 1 Position the liftgate trim panel aside. 2 Remove the access the covers and the liftgate window hinge nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 11810 NOTE: An assistant may be needed to carry out this step. 6. Remove the liftgate window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed Quarter Window Glass: Service and Repair Fixed REMOVAL 1. Remove the quarter trim panel. 2. Remove the rear quarter window glass. 1 Remove the nuts. 2 Push the rear quarter window glass outward to release the butyl seal. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. ^ Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass. 1 Position the rear quarter window glass. 2 Tighten the nuts. NOTE: Loosely install the nuts before tightening. 3. Install the quarter trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 11815 Quarter Window Glass: Service and Repair Movable Quarter REMOVAL 1. Remove the quarter trim panel. 2. Remove the quarter window glass. 1 Remove the nuts. 2 Remove the quarter window glass. INSTALLATION 1. To install, reverse the removal procedure. ^ If the seal requires adjustment, disconnect the quarter window latch from the quarter trim panel. Rotate the quarter window latch clockwise to increase seal pressure or counterclockwise to reduce seal pressure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Remove the rear door trim panel. 2. Remove the interior glass weatherstrip. 3. Remove the rear door belt line moulding nut. 4. Remove the rear door belt line moulding. CAUTION: Do not strike or force the front door belt line moulding during the installation. The front door belt line moulding is made of aluminum and will be damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 11819 NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge of the sheet metal and the door panel shelf. 5. Remove the rear door window glass rivets. 6. Remove the rear door window glass through the outboard side of the rear door. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the interior door handle. 3. Support the front door window glass. 4. Disconnect the front door window regulator motor electrical connector. 5. Remove the equalizer bracket nuts. 6. Remove the front door window regulator. 1 Remove the rivets. 2 Remove the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11824 7. Remove the front door window regulator motor. 1 Remove the bolts. 2 Remove the front door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11825 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Raise and support the rear door window glass to the full up position. 2. Remove the interior door handle. 3. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 4. Remove the water shield. 5. Disconnect the rear door window regulator motor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 11829 6. Remove the rear door window regulator rivets. 7. Remove the rear door window regulator. ^ Slide the regulator arms off of the window glass track. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 11830 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information Windshield: Technician Safety Information WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information > Page 11835 Windshield: Vehicle Damage Warnings CAUTION: ^ After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (refer to Essex Drive Away Chart for cure times, as temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane bond. ^ Do not scratch the pinch weld area. ^ If the vehicle is to be driven within 24 hours of urethane application, urethane adhesive Essex U-216 must be used due to its one hour cure time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11836 Windshield: Service and Repair SPECIAL TOOL(S) REMOVAL WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. 1. Remove the windshield side garnish mouldings. 2. Remove the interior rear view mirror. 3. Remove the overhead console. 4. Remove the sun visors. 1 Remove the sun visor screws. 2 Remove the sun visors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11837 ^ if equipped, disconnect the electrical connector. 5. Remove the sun visor clips. 1 Remove the sun visor clip screws. 2 Remove the sun visor clips. 6. Lower the front portion of the headliner. 7. Remove the cowl grille. 8. Remove the upper windshield weatherstrip. 9. Remove the LH and RH windshield mouldings. 10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld. 11. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and work toward the bottom corners. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11838 NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting. 12. Using the special tool, distance the windshield from the body. 13. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass. 14. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. INSTALLATION CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (refer to Essex Drive Away Chart for cure times, as temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane bond. 1. Dry fit the windshield. Make alignment marks with tape or non-staining grease pencil. 2. Trim the remaining urethane adhesive on the pinch weld to within the specification. ^ The existing urethane adhesive surface should be smooth and free of cuts and contamination. CAUTION: Do not scratch the pinch weld area. 3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to ten minutes to dry. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11839 4. Apply (A) Foam Dam meeting Ford specification WSB-M2G234-C to the (B) pinch weld. 5. If reinstalling original windshield, remove the excess urethane adhesive from the windshield glass. 6. Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic coated area is clean. 7. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be urethaned. NOTE: Wipe off the Glass Prep immediately after each application because it flash dries. 8. If installing a new windshield glass, apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the pervious step. Allow five minutes to dry. 9. Cut the urethane adhesive applicator tip to specification. 10. Apply a bead of urethane adhesive Essex 400-HV or Essex U-216, which meets Ford specification WSB-M2G316-B to the pinch weld just outside the foam dam. CAUTION: If the vehicle is to be driven within 24 hours of urethane application, urethane adhesive Essex U-216 must be used due to its one hour cure time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11840 11. Install the windshield glass aligning it to the marks previously made. 12. After the windshield glass is set, check for water leaks and add urethane adhesive where needed. 13. Install the upper windshield weatherstrip. 14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass. 15. Install the LH and RH windshield mouldings. 16. Install the cowl grille. 17. Install the overhead console. 18. Install the sun visor clips. 1 Position the sun visor clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11841 19. Install the sun visors. 1 Position the sun visors. ^ If equipped, connect the electrical connector. 2 Install the screws. 20. Install the front portion of the headliner. 21. Install the interior rear view mirror. 22. Install the windshield side garnish mouldings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11842 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11850 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11851 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11852 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11853 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11854 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11855 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11856 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11857 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11858 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11859 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11860 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11861 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11862 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11863 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11864 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11865 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11866 Windshield Washer Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11867 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11868 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11869 Windshield Washer Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11870 Windshield Washer Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 11871 Windshield Washer Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay, Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay, Front > Page 11877 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 11878 Windshield Washer Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 11879 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11885 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11886 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11887 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11888 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11889 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11890 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11891 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11892 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11893 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11894 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11895 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11896 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11897 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11898 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11899 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11900 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11901 Wiper Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11902 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11903 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11904 Wiper Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11905 Wiper Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11906 Wiper Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 11912 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 11913 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 11914 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 11915 Wiper Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 11916 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11921 Windshield Washer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11922 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 11927 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 11928 Wiper Switch: Diagrams Multi-Function Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11929 Wiper Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11930 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11931 Wiper Switch: Service and Repair REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11937 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11938 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11939 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11940 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11941 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11942 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11943 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11944 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11945 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11946 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11947 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11948 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11949 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11950 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11951 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11952 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11953 Windshield Washer Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11954 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11955 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11956 Windshield Washer Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11957 Windshield Washer Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 11958 Windshield Washer Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions Windshield Washer Pump: Service Precautions WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF THE WASHER SOLUTION CONTAINER. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Page 11965 Windshield Washer Pump: Service and Repair REMOVAL 1. Remove the engine air cleaner; refer to Fuel Delivery and Air Induction. 2. Remove the windshield wiper reservoir fasteners. 1 Remove the two screws. 2 Remove the two nuts. 3. Disconnect the windshield washer reservoir pump electrical connector. 4. Disconnect the windshield washer hose from the windshield washer pump and plug the outlet of the pump. WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF THE WASHER SOLUTION CONTAINER. 5. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the outlet of the reservoir. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Page 11966 6. Remove the windshield washer pump. NOTE: Make sure not to damage the rubber grommet during disassembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay, Front Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay, Front > Page 11972 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 11973 Windshield Washer Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 11974 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11978 Windshield Washer Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11979 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the passenger windshield wiper blade and the rear edge of the cowl top vent panel is within specifications. 3. Verify the distance between the center of the driver windshield wiper blade and the rear edge of the cowl top vent panel is within specifications. 4. If the distance is not within specifications, remove the windshield wiper pivot arms and reposition to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front Wiper Arm: Service and Repair Pivot Arm-Front REMOVAL 1. Remove the wiper pivot arm. 1 Pull up on the wiper pivot arm. 2 Pull out on the retainer tab and lower the wiper pivot arm to the tab. 3 Remove the wiper pivot arm. NOTE: The wiper pivot arms are installed as an assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front > Page 11985 Wiper Arm: Service and Repair Pivot Arm-Rear REMOVAL 1. Disconnect the rear washer hose. 2. Remove rear wiper pivot arm. 1 Lift the wiper pivot arm nut cover at the point shown. 2 Remove the nut. 3 Remove the wiper pivot arm. NOTE: The wiper pivot arm must be lifted straight up from the shaft to avoid damage to the wiper pivot arm or shaft. INSTALLATION 1. Turn the rear wiper switch on and allow the motor to operate for at least one cycle. 2. Turn the rear wiper switch OFF. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front > Page 11986 NOTE: This step makes sure that the wiper motor is in the park position. 3. Position the rear wiper blade outside the wiper arm stop. 4. Install the wiper pivot arm onto the wiper motor. ^ Tighten retaining nut. 5. Connect the washer hose to the elbow with elbow positioned between the 9:00 and 12:00 o'clock positions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments Wiper Blade: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the passenger windshield wiper blade and the rear edge of the cowl top vent panel is within specifications. 3. Verify the distance between the center of the driver windshield wiper blade and the rear edge of the cowl top vent panel is within specifications. 4. If the distance is not within specifications, remove the windshield wiper pivot arms and reposition to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Locations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions Early Production/Late Production Defined NOTE: The build date can be found on the Vehicle Certification (VC) label. Early Production Built BEFORE 7/24/2000. Uses the Remote Anti-Theft Personality (RAP) Module. Late Production Built AFTER 7/24/2000. Uses the Central Security Module. How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Note: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11995 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number in the A-Z Component List, the Component Location description for that component can easily be found. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11996 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11997 Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. The Component Location Views show the components and their connecting wires as they can be found on the vehicle. The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11998 Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11999 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12000 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12001 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12002 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12003 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12004 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12005 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12006 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12007 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12008 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12009 Types of Diagrams Shown Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. Wire Color Code Identification Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12010 Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12011 Wiper Control Module: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12012 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12013 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12014 Wiper Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12015 Wiper Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Diagrams. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 12016 Wiper Control Module: Application and ID For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module). Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield Wiper Motor Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield Wiper Motor > Page 12022 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 12023 Wiper Motor: Service Precautions CAUTION: ^ The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. ^ Read the installation label on the rear wiper motor before installing in vehicle to prevent component damage. Do not activate rear wiper motor until windshield wiper arm and blade are correctly installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 12024 Wiper Motor: Testing and Inspection Use Alternator, Regulator, battery and Starter Tester (ARBST) to test the wiper motor on the vehicle. To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. Disconnect the wiper motor. Connect the (1) green lead from (2) Alternator, Regulator, Battery and Starter Tester (ARBST) to the battery negative (-) post. Connect the (3) red lead from ARBST to the wiper motor (4) common brush terminal (terminal 3). Test the low speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than 3.5 amperes, install a new windshield wiper motor. Test the high speed mode by connecting a cable from the battery positive (+) post to the (7) high speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than 5.5 amperes, install a new wiper motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor Wiper Motor: Service and Repair Windshield Wiper Motor REMOVAL 1. Disconnect the washer hose from the LH washer jet nozzle. 2. Remove the cowl grilles. 3. Unsnap the wiper motor clip from the RH wiper mounting arm and pivot shaft. 4. Disconnect the RH wiper mounting arm and pivot shaft from the LH wiper mounting arm and pivot shaft and move both away from the windshield wiper motor. 5. Disconnect the electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 12027 6. Remove the ground strap nut and position the strap aside. 7. Remove the windshield wiper motor. ^ Remove the stud bolts. ^ Remove the bolts. CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. INSTALLATION 1. Install the windshield wiper motor. 1 Install the windshield wiper motor. 2 Install the stud bolts. 3 Install the bolts. CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 12028 2. Install the ground strap and nut. 3. Connect the electrical connector. 4. Install the wiper mounting arm and pivot shaft arms to the windshield wiper motor. 1 Install the LH wiper mounting arm and pivot shaft onto the windshield wiper motor crank pin. 2 Install the RH wiper mounting arm and pivot shaft onto the wiper motor crank pin. 3 Push the retaining clip until it snaps into place. 5. Install the cowl grilles. 6. Connect the washer hose to the LH washer jet nozzle. 7. Install the LH wiper pivot arm. 8. Adjust the LH wiper pivot arm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 12029 Wiper Motor: Service and Repair Rear Window Wiper Motor REMOVAL 1. Remove the rear wiper pivot arm. 2. Remove the liftgate door trim panel. 3. Remove the watershield. 4. Remove rear wiper motor. 1 Disconnect electrical connector. 2 Remove three retaining bolts. 3 Remove rear wiper motor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Read the installation label on the rear wiper motor before installing in vehicle to prevent component damage. Do not activate rear wiper motor until windshield wiper arm and blade are correctly installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service Precautions Wiper Motor Linkage: Service Precautions CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield wiper motor crank pin. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service Precautions > Page 12033 Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove the cowl grilles. 2. Unsnap the wiper motor clip from the RH wiper mounting arm and pivot shaft. 3. Disconnect the RH wiper mounting arm and pivot shaft from the LH wiper mounting arm and pivot shaft and move both away from the windshield wiper motor. 4. Remove the RH and LH wiper mounting arm and pivot shafts. 1 Remove the two nuts. 2 Remove the wiper mounting arm and pivot shafts. INSTALLATION 1. Install the RH and LH wiper mounting arms and pivot shafts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service Precautions > Page 12034 1 Position the wiper mounting arm and pivot shafts into place. 2 Install the two nuts. 2. If removed, install the clip onto the RH wiper mounting arm and pivot shaft. CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield wiper motor crank pin. 3. Install the wiper mounting arm and pivot shaft assemblies. 1 Install the LH wiper mounting arm and pivot shaft onto the windshield wiper motor crank pin. 2 Install the RH wiper mounting arm and pivot shaft onto the wiper motor crank pin. 3 Push the retaining clip until it snaps into place. 4. Install the cowl grilles. 5. Adjust the LH and RH wiper pivot arms. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Diagram 700-01-00-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 12040 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 12041 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 12042 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 12043 Wiper Relay: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 12044 COMPONENT TESTING PROCEDURE (Voltage Applied) Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V , continue with the test. If not, replace the relay. Disconnect power from pin 2 and measure voltage between pin 4 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 12049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Rear Window Wiper Disable Switch > Page 12050 Wiper Switch: Diagrams Multi-Function Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12051 Wiper Switch: Testing and Inspection Component Testing Instructions Component testing procedures are provided to determine whether a component is good or bad. Testing information for each component includes a schematic with component terminal locations and step-by-step test procedures. Component terminals are identified by letters or numbers that may be marked on the component or callout if there is no mark on the component. The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column TO TEST. If you wish to test the complete component, perform all tests. Connect the tester to the terminals shown in the second column and operate the component as shown in the third column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12052